Thermal analysis of SUS 304 stainless steel using ethylene glycol/nanocellulose-based nanofluid coolant

Green cooling system usage in machining is getting favors to minimize the environmental effect such as pollutions. Around 20% of the machining cost is about coolant usage in flooded cooling technique. Even though coolant has a reasonably low cost, their handling and disposing cost are very high and also, threatening toxic contents, disposal of used coolant is a big problem as it can lead to hazardous effect to the machining operates as well as to the environment. As an alternative, a cooling technique known as minimum quantity lubrication (MQL) was introduced in the machining operation. For MQL technique, the coolant should exhibit superior properties which are effective in machining operation when compared with the conventional machining coolant which is metal working fluid (MWF). Owing to the technology advancements by nanotechnology in nanomaterial, the nanofluid is a promising coolant that can replace the conventional machining coolant. In the present work, ethylene glycol/nanocellulose-based nanofluid is evaluated in terms of its thermo-physical properties and its effectiveness in machining performances which is temperature distribution in cutting tool and compare its effectiveness with MWF. Its effectiveness is tested in turning machining operation of SUS 304 stainless steel using cemented tungsten-cobalt (WC-Co)-coated carbide cutting insert. The turning operation by using ethylene glycol/nanocellulose-based nanofluid coolant with 0.5 vol% which exhibit a superior thermal conductivity of 0.449 W/m K than 0.267 W/m K thermal conductivity of MWF at 30 °C. The recorded lower amount of heat transfer to the cutting tool is 863 J compared with 1130 J when using MWF. On the other hand, the maximum temperature reading recorded at chip formed by using MWF is 225 °C whereas by using nanofluid is 154 °C which promises lower temperature distribution to chip formed during the machining operation. Also, the functionality of nanofluid as a thermal transport during machining is proven via chip formation observation analysis and scanning electron microscope (SEM) with energy-dispersive X-ray (EDX) spectrum analysis

Development and analysis of Ethylene Glycol/Nanocellulose based Nanofluid Coolant for machining SUS 304 stainless steel

In the manufacturing industry nowadays, machining plays a significant role. When the machining operation is carried out, the temperature rises with the speed and the tool strength decreases, leading to faster wear and tool failure. Thus, it is essential to cool down the heat generated at the tool and work piece interface for a better tool life via effective cooling system. This thesis discusses the effectiveness of Ethylene Glycol/Nanocellulose based Nanofluid Coolant (EGN-NFC) in term of its thermophysical properties such as thermal conductivity and viscosity. Besides that, its’ effectiveness is evaluated and analysed in term of machining performances such as surface roughness, temperature distribution, tool wear, chip formation and tool life during turning machining operation of SUS304 stainless steel through the Box Behnken design of experiment using cemented tungsten-cobalt (WC-Co) coated carbide grade with Ti (C,N) + Al2O3 insert. The effectiveness of the EGN-NFC is compared with the conventional machining coolant which is metal working fluid (MWF). The mathematical model equation for surface roughness was developed using response surface methodology (RSM). The cutting variables are cutting speed, feed rate, and depth of cut. The developed model equations for the surface roughness shows that the most significant input parameter is the feed rate, followed by depth of cut and cutting speed. The turning operation by using EGN-NFC obtains lower surface roughness, achieved greater total length of cut prior to reach the ISO 3865:1977 wear criterion, low temperature distribution and produce discontinuous chip compared with turning operation by using MWF. The cutting tool in turning operation using EGN-NFC take longer time to wear when compare with the one using MWF as the coolant. According to ISO 3865:1977 the wear criteria for turning using MWF reached the maximum total length of cut of 500 mm but the maximum total length of cut for turning using EGN-NFC reached the wear criteria at the cutting distance of 750 mm. The SEM and EDX spectrum shows there are an interfacial layer of nanocellulose from the EGN-NFC embedded and fills the holes in the insert and for a layer which act as an additional protective layer and thermal bridge for the cutting insert. Build-up-edge (BUE), diffusion and adhesion at the cutting edge were the main tool wear mechanism present during turning operation using EGN-NFC. The usage of EGN-NFC in turning operation also helps to reduce the effect of cutting and friction forces during machining operation through discontinuous chip formation results from low cutting temperature. For optimum turning machining performances using EGN-NFC with minimum surface roughness and maximum total length of cut with tool life to be achieved, the parameters been optimized using Minitab to be cutting speed equals to 140 m/min, feed rate equals to 0.05 mm/rev and depth of cut equals to 0.5 mm

State of art of cooling method for dry machining

The usage of cutting fluid in the machining operations will not only poses health risk to the workers but also creates environmental challenges associated with fluid treatment and disposal. The objective of this review paper is to identify present cooling method in dry machining and novel feature than can be included in the cooling system for a better heat removal which tend to increase machining performance. From the review study, it shows that cooling method by internal manner is most widely been researched because researcher believes that it has a promising future in adaptive machining to produce a contamination free products which supports the green manufacturing concept. The suggested novel feature is ecologically desirable and it will become as a necessity for improving the performance of dry machining in the near future

State of Art of Cooling Method for Dry Machining

The usage of cutting fluid in the machining operations will not only poses a health risk to the workers but also creates environmental challenges associated with fluid treatment and disposal. In an effort to minimize these concerns, various cooling method have been reviewed and the comparison among them have been tabulated. Internal cooling system for dry machining has a promising future in adaptive machining to produce contamination free products. This paper also highlights the novel feature for cooling system to improve dry machining which uses the conventional turning machine. This developed novel feature is ecologically desirable and it will be considered as a necessity for dry machining in the near future

Multi-objective optimization on the machining parameters for bio-inspired nanocoolant

The emphasis of this paper is to evaluate the thermophysical properties of crystalline nanocellulose (CNC)-based nanofluid and the optimized machining parameters (cutting speed, feed rate and depth of cut) for machining using CNC-based nanofluid. Cutting tool temperature and formed chip temperature during machining are determined with CNC-based coolant and metal working fluid. Minimum quantity lubrication technique is used to minimize the usage of the coolant. Nanocellulose coolant with a concentration of 0.5% shows better thermal conductivity and viscosity. Total heat produced at the cutting tool and the temperature generated at the chip during machining shows significant improvement using CNCbased nanofluid. Statistical analysis reveals that feed rate and depth of cut contribute around 27.48% and 22.66% toward cutting temperature. Meanwhile, none of the parameters significantly affects the heat transfer. The multi-objective optimization reveals that the optimum parameter for machining using CNC-based nanocoolant is: cutting speed = 120, feed rate = 0.05 and depth of cut = 1.78 which produces heat transfer of 379.44 J and cutting temperature of 104.41 C

Thermal analysis of cellulose nanocrystal-ethylene glycol nanofluid coolant

In this paper, cellulose nanocrystal (CNC) – ethylene glycol (EG) + Water (W) based nanofluid was developed and assessed for their thermophysical properties and the usefulness towards machining performances. The nanofluid was prepared by adopting two-step preparation method and at volume concentration of 0.1%, 0.3%, 0.5%, 0.7%, 0.9%, 1.1%, 1.3% and 1.5%. The nanofluid with 1.3% and 1.5% concentration showed to have superior the conductivity properties, around 0.559 W/m·K at 70 °C. However, the 0.5% concentration has the highest stability with 0.52 W/m·K at 70 °C. The 0.5% nanofluid concentration was then selected for the machining performance evaluation. The machining performance was evaluated by using a lathe machining operation to determine the heat transfer and tool life properties. The cutting variables such as cutting speed, depth of cut and feed rate are varied to understand the effect of developed nanofluid on the machining bahaviour. Findings revealed that the tool failure on machining using MWF is flank wear, chipping and abrasion and fractured at the maximum cutting distance of 500 mm. However, machining using CNC-EG+W nanofluid revealed the tool failure to be flank wear, adhesion and build- up-edge (BUE) and fractured at the maximum cutting distance of 772 mm