Parameter analysis of copper-nickel-tungsten prepared via powder metallurgy process for electrical discharge machining of polycrystalline diamond

Polycrystalline Diamond (PCD) tools have an outstanding wear resistance. The electric conductivity of PCD caused by the conductive binding material (Cobalt) makes it possible to machine PCD tools with EDM. Electrode used in EDM of PCD must have better porosity, electrical and thermal conductivity. Therefore, this research presents the works in production of Cu-Ni-W electrode by powder metallurgy route. Production of powder metallurgy parts involve mixing of the powder with additives or lubricants, compacting the mixture and heating the green compacts in an Argon gas furnace so the particle bond to each other. Two levels of full factorial with six centre points and two replication technique was used to study the influence of main and interaction effects of the powder metallurgy parameter. There were four factors involved in this experiment. Factor A which is Type of Cu-Ni; Type A and Type B was defined as categorical factor. Factor B in which Composition of W; 5 Wt.%, 15 Wt. % and 25 Wt.%, was defined as numerical factor. Factor C which is the Compaction load; 7, 8 and 9 tonne and Factor D which is Sintering temperature; 635 ℃, 685 ℃ and 735 ℃ were also defined as numerical factor. Optical Microscope, Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) was used to analysed the microstructure and surface morphology of Cu-Ni-W electrode. The best parameter combination to produced better porosity, electrical and thermal conductivity for both Type A and Type B was 5 Wt.% of W, compaction load at 9 tonne and sintering temperature at 735℃. The best response for Type A is 12.65% of porosity, 14.40 IACS% of electrical conductivity and 413.26 W/m.℃ of thermal conductivity. While that, the best response for Type B were 9.36% of porosity, 16.66 IACS% of electrical conductivity and 345.21W/m.℃ of thermal conductivity. From the calculation of Maxwell’s Equation, Type A and Type B had the highest electrical conductivity of 58.48 IACS% and 77.35 IACS% respectively at W content of 5Wt.%. Type A and Type B also had the highest thermal conductivity of 369.86 W/m.℃ and 310.24 W/m.℃ respectively at W content of 5 Wt.%. Besides that, thermal conductivity also increased with the temperature increased until 450℃

Machinability Evaluation of Nanoparticle Enriched in Vegetable-Based-Nanofluids for Machining Process

Vegetable oil had been study to replace mineral based oil as metalworking fluids (MWFs) as it is non toxic, bio-degradable and environmental friendly. Due to vegetable oil’s high viscosity and poor thermal conductivity, some improvement had been applied to vegetable oil such as chemically modified and the addition of additives. The aim of this study to evaluate the machining performance of modified jatropha oil (MJO) with nanoparticle additives of 0.025wt% copper oxide(Cuo) (MJOc) and 0.025wt% hexagonal boron nitride(hBN) (MJOh) as metalworking fluids. The machining performance of MJOc and MJOh were compared with the commercial synthetic ester (SE) through turning process in terms of cutting temperature, surface roughness, tool life and tool wear. The result show that the machining performance of MJOc and MJOh were better compared to SE. In terms of cutting temperature and surface roughness, MJOh shows better maching performance compared to MJOc. In addition, MJOh had same tool life performance with SE which is at cutting length of 6000mm and machining time of 42 minutes. In conclusion, the overall best machining performance is MJOh (MJO+0.025wt% hBN) and has a potential as sustainable MWFs in lubricant market

Evaluation of physicochemical and tribological performances of hBN/WS2 and hBN/TiO2 hybrid nanoparticles-MJO-based oil

This work aims to investigate the physicochemical and tribological performance of modified Jatropha oil (MJO) with the addition of 0.025 wt.% of hexagonal boron nitride (hBN) + Titanium dioxide (TiO2) (MJOht) and hBN + tungsten disulphide (WS2) (MJOhw). The physicochemical properties of the samples were evaluated through kinematic viscosity and viscosity index. Four ball test was used to determine the tribological performance of the samples. All the MJO samples were compared with the benchmark oil, Synthetic Ester (SE). The result revealed that MJOht has excellent physicochemical properties in kinematic viscosity of 20.79 mm2/s at 40 °C and 6.29 mm2/s at 100 °C. MJOht also had the highest viscosity index (288). For tribological performance, MJOhw has an excellent coefficient of friction (COF) (0.0574) and lowest surface roughness (Ra) (0.11 μm)., while MJOht shows a smaller mean wear scar diameter (MWSD) (718.6 µm). Overall, MJO with hybrid additives shows excellent performance on physicochemical and tribological properties and making it a feasible choice as a green metalworking fluid

Analysis Performance of Modified Tamanu Oil Enhanced with Additives as Potential Green Alternative in Metalworking Fluids

Mineral oils have long been utilized in industries as machining lubricants, which contributed to their depletion and hick in price and being non-biodegradable, harmful to the environment, and risk to health. Plant-based oil is more biodegradable, renewable, and environmentally friendly as a green alternative. However, in their crude state, plant-based oils are not up to par with the standard mineral oil used in lubrication in terms of high acidity, low-temperature performance, and oxidative instability. Further chemical modification and adding additives had to be made to improve the oil properties for industrial applications. This study focused on the performance of transesterification of Tamanu plant-based oil with Trimethylolpropane (MTO) and Pentaerythritol (MTOP), which mixed with 1% of Phosphonium Ionic Liquid (PIL) and 10% of Ammonium Ionic Liquid (AIL), producing a series of oil specimens; MTO, MTO+PIL1%, MTO+AIL%, MTOP, MTOP+PIL1%, and MTOP+AIL%. These samples are then subjected to physical analysis to determine the improvement of their properties in terms of kinematic viscosity and viscosity index as well as undergo a four-ball wear test to the determine the tribology aspects of the lubrication in terms of coefficient of frictions and wear scar diameter, in accordance with ASTM standard method. All the results were compared with commercial MWF which synthetic ester (SE) as reference oil. The result of viscosity index reveals that MTOP+PIL1% had the highest value of 178.76. MTO+AIL10% exhibits the lowest average COF (0.061) compared to other MTOs lubricants. Among MTOP, MTOP+PIL1% also had the lowest average COF which is 0.082. The addition of PIL1% to MTO and MTOP lowered the average scar diameter, 730.77 μm and 674.93μm respectively. With the enhanced properties from chemical modification and additives, Tamanu oil can be proposed as a green alternative for developing the metalworking fluid industries in the future

Analysis Performance of Modified Tamanu Oil Enhanced with Additives as Potential Green Alternative in Metalworking Fluids

Mineral oils have long been utilized in industries as machining lubricants, which contributed to their depletion and hick in price and being non-biodegradable, harmful to the environment, and risk to health. Plant-based oil is more biodegradable, renewable, and environmentally friendly as a green alternative. However, in their crude state, plant-based oils are not up to par with the standard mineral oil used in lubrication in terms of high acidity, low-temperature performance, and oxidative instability. Further chemical modification and adding additives had to be made to improve the oil properties for industrial applications. This study focused on the performance of transesterification of Tamanu plant-based oil with Trimethylolpropane (MTO) and Pentaerythritol (MTOP), which mixed with 1% of Phosphonium Ionic Liquid (PIL) and 10% of Ammonium Ionic Liquid (AIL), producing a series of oil specimens; MTO, MTO+PIL1%, MTO+AIL%, MTOP, MTOP+PIL1%, and MTOP+AIL%. These samples are then subjected to physical analysis to determine the improvement of their properties in terms of kinematic viscosity and viscosity index as well as undergo a four-ball wear test to the determine the tribology aspects of the lubrication in terms of coefficient of frictions and wear scar diameter, in accordance with ASTM standard method. All the results were compared with commercial MWF which synthetic ester (SE) as reference oil. The result of viscosity index reveals that MTOP+PIL1% had the highest value of 178.76. MTO+AIL10% exhibits the lowest average COF (0.061) compared to other MTOs lubricants. Among MTOP, MTOP+PIL1% also had the lowest average COF which is 0.082. The addition of PIL1% to MTO and MTOP lowered the average scar diameter, 730.77 μm and 674.93μm respectively. With the enhanced properties from chemical modification and additives, Tamanu oil can be proposed as a green alternative for developing the metalworking fluid industries in the future

Tribological performance of novel modified calophyllum inophyllum nano-fluid from Pahang, Malaysia

This study aims to examine the performance of modified Calophyllum Inophyllum oil (MCIO) added with activated carbon made from the Calophyllum Inophyllum (CI) fruit shells as nano additives to enhance the oil performance as lubricants on friction and wear characteristics. This ecofriendly nanofluid is formulated by combining the nanoactivated carbon with MCIO using homogenization and sonication techniques. These nanofluid samples are subjected to physical analysis according to ASTM standards to determine their kinematic viscosity and viscosity index. A four-ball wear test is conducted for investigating the fluid's tribological performance. It was revealed that the formulation of MCIO containing 0.025 wt. % nano-activated carbon has the lowest coefficient of friction of 0.0551, with wear scar diameter of 724.2 µm and wear rate 5.91 × 10-7 mm. The novel MCIO with activated-carbon nano additive demonstrated superior lubricant performance compared to synthetic ester, neat MCIO, and MCIO + 0.025 wt. % NC based on the tribological performance shown

The tribological performance of nano-activated carbon as solid additives in modified calophyllum inophyllum based-metalworking fluid

Biolubricants have attracted attention in today’s market as a new alternative to commercial lubricants due to their environmentally friendly and renewable properties. The refinement of bio-lubricants has improved their tribological and physical properties. However, to optimize the performance of lubricants when machined under high-temperature conditions, additives must be added to the lubricant. In this study, the tribological properties of modified Calophyllum inophyllum (MTO) oil combined with nano-activated carbon (NAC) as additives were investigated using the four-ball wear test method. This bio-lubricant consists of modified Calophyllum inophyllum oil in combination with NAC at concentrations of 0.01, 0.025, and 0.05 wt%. The coefficient of friction for the balls and their wear diameter are evaluated and compared. The kinematic viscosity and viscosity index of MTO were tested according to ASTM standards. The results show that a lubricant with added NAC is more effective in reducing wear and friction than a bio-lubricant without nanoactivated carbon. The bio-lubricant combined with NAC reduced the wear diameter of the lubricated balls compared to the bio-lubricant without additives. The nanoadditives have converted the sliding effect into a ball-bearing effect between the interfaces of the balls, creating a better oil protective film that helps form a gap between the mating surfaces during tribological testin

The tribological performance of nano-activated carbon as solid additives in modified calophyllum inophyllum based-metalworking fluid

Biolubricants have attracted attention in today’s market as a new alternative to commercial lubricants due to their environmentally friendly and renewable properties. The refinement of bio-lubricants has improved their tribological and physical properties. However, to optimize the performance of lubricants when machined under high-temperature conditions, additives must be added to the lubricant. In this study, the tribological properties of modified Calophyllum inophyllum (MTO) oil combined with nano-activated carbon (NAC) as additives were investigated using the four-ball wear test method. This bio-lubricant consists of modified Calophyllum inophyllum oil in combination with NAC at concentrations of 0.01, 0.025, and 0.05 wt%. The coefficient of friction for the balls and their wear diameter are evaluated and compared. The kinematic viscosity and viscosity index of MTO were tested according to ASTM standards. The results show that a lubricant with added NAC is more effective in reducing wear and friction than a bio-lubricant without nanoactivated carbon. The bio-lubricant combined with NAC reduced the wear diameter of the lubricated balls compared to the bio-lubricant without additives. The nanoadditives have converted the sliding effect into a ball-bearing effect between the interfaces of the balls, creating a better oil protective film that helps form a gap between the mating surfaces during tribological testin

Effect of vegetable-based nanofluid enriched with nanoparticles as metalworking fluids during orthogonal cutting process

The growing interest in the usage of vegetable oils as a based fluid for the lubrication industry led to more study on the potential of vegetable oils as MWFs to replace the mineral-based oil due to the environmental benefits such as renewable and biodegradable. In this study, vegetable-based nanofluids were formulated from modified jatropha oils (MJO) mixed with nanoparticle additives copper oxide and activated carbon at different concentration of 0.01, 0.025 and 0.05wt.%. The aim of this study was to evaluate the machining performance of the nanofluids (MJOc1, MJOc2, MJOc3, MJOa1, MJOa2 and MJOa3) compared with the commercial synthetic ester (SE)in terms of cutting temperature and chip thickness. The lathe machine (Harrison alpha 400) was used for orthogonal cutting with the minimum quantity lubrication (MQL) method. Thermal imager camera FLIR T640 used in this experiment to measure the maximum cutting temperature by placing the camera in an axial direction during the machining process. Then, a micrometre (model: Mitutoyo IP 65) used in this experiment to measure the chip thickness while a tool maker measuring microscope used to measure the tool chip contact length after the experimental process. MJO with nanoparticle additions has the potential to replace SE as a long-term metalworking fluid

Effect of Vegetable-Based Nanofluid Enriched with Nanoparticles as Metalworking Fluids During Orthogonal Cutting Process

The growing interest in the usage of vegetable oils as a based fluid for the lubrication industry led to more study on the potential of vegetable oils as MWFs to replace the mineral-based oil due to the environmental benefits such as renewable and biodegradable. In this study, vegetable-based nanofluids were formulated from modified jatropha oils (MJO) mixed with nanoparticle additives copper oxide and activated carbon at different concentration of 0.01, 0.025 and 0.05wt.%. The aim of this study was to evaluate the machining performance of the nanofluids (MJOc1, MJOc2, MJOc3, MJOa1, MJOa2 and MJOa3) compared with the commercial synthetic ester (SE)in terms of cutting temperature and chip thickness. The lathe machine (Harrison alpha 400) was used for orthogonal cutting with the minimum quantity lubrication (MQL) method. Thermal imager camera FLIR T640 used in this experiment to measure the maximum cutting temperature by placing the camera in an axial direction during the machining process. Then, a micrometre (model: Mitutoyo IP 65) used in this experiment to measure the chip thickness while a tool maker measuring microscope used to measure the tool chip contact length after the experimental process. MJO with nanoparticle additions has the potential to replace SE as a long-term metalworking fluid