Performance evaluation of biodegradable metalworking fluids for machining process

The widely use of metalworking fluids (MWFs) petroleum-based in the industry have a negative impact to the environment and human. Thus, various initiatives have been undertaken to develop bio-based MWFs especially from crude jatropha oil (CJO). However, the main drawback of CJO is that it has low thermal-oxidative stability. Therefore, the objective of this study is to develop a new formulation of CJO-based MWFs. The newly developed modified jatropha oils (MJOs) were formulated using transesterification process at various molar ratios of jatropha methyl ester to trimethylolpropane (JME:TMP) denoted by MJO1 (3.1:1), MJO3 (3.3:1) and MJO5 (3.5:1). Later, the MJOs were blended with hexagonal boron nitride (hBN) particles at various concentrations (0.05 to 0.5wt.%). MJOs with and without hBN particles were analysed based on the physicochemical properties, tribology behaviour test, orthogonal cutting and turning proses. From the results, MJO5 showed an improvement at thermal (high viscosity index) and oxidative stability (lubricant storage). MJO5c (MJO5+0.5wt.% of hBN particles) showed the optimum physicochemical properties. In the contrary, MJO5a (MJO5+0.05wt.% of hBN particles) exhibited excellent tribological behaviour as reduction of friction and wear, with high tapping torque efficiency. In the orthogonal cutting process, MJO5a recorded the lowest machining force and temperature, thus contributed to the formation of thinner chips, small tool-chip contact length and reduction of the specific energy. MJO5a produced an excellent result in the machinability test by reducing the cutting force, cutting temperature and surface roughness stimulated longer tool life and less tool wear. In conclusion, the MJO5a has a potential impact on the lubricant market as a sustainable MWFs for the machining processes

Performance evaluation of biodegradable metalworking fluids for machining process

The widely use of metalworking fluids (MWFs) petroleum-based in the industry have a negative impact to the environment and human. Thus, various initiatives have been undertaken to develop bio-based MWFs especially from crude jatropha oil (CJO). However, the main drawback of CJO is that it has low thermal-oxidative stability. Therefore, the objective of this study is to develop a new formulation of CJO-based MWFs. The newly developed modified jatropha oils (MJOs) were formulated using transesterification process at various molar ratios of jatropha methyl ester to trimethylolpropane (JME:TMP) denoted by MJO1 (3.1:1), MJO3 (3.3:1) and MJO5 (3.5:1). Later, the MJOs were blended with hexagonal boron nitride (hBN) particles at various concentrations (0.05 to 0.5wt.%). MJOs with and without hBN particles were analysed based on the physicochemical properties, tribology behaviour test, orthogonal cutting and turning proses. From the results, MJO5 showed an improvement at thermal (high viscosity index) and oxidative stability (lubricant storage). MJO5c (MJO5+0.5wt.% of hBN particles) showed the optimum physicochemical properties. In the contrary, MJO5a (MJO5+0.05wt.% of hBN particles) exhibited excellent tribological behaviour as reduction of friction and wear, with high tapping torque efficiency. In the orthogonal cutting process, MJO5a recorded the lowest machining force and temperature, thus contributed to the formation of thinner chips, small tool-chip contact length and reduction of the specific energy. MJO5a produced an excellent result in the machinability test by reducing the cutting force, cutting temperature and surface roughness stimulated longer tool life and less tool wear. In conclusion, the MJO5a has a potential impact on the lubricant market as a sustainable MWFs for the machining processes

Investigation on the Tribological Behaviour of Modified Jatropha Oil with Hexagonal Boron Nitride Particles as a Metalworking Fluid for Machining Process

Bio-based oil from vegetable oils was recently explored as an alternative solution to petroleum-based oil. However, the application of vegetable oils as metalworking fluids (MWFs) for machining process is still not widespread. The objective of this study was to investigate the tribological behaviour of modified vegetable oils, in comparison with synthetic ester (SE) and crude jatropha oil (CJO). In this study, the CJO was chemically modified via transesterification process to develop modified jatropha oil (MJO5). MJO5 was then blended with the hexagonal boron nitride (hBN) particles at various concentrations ranging between 0.05 to 0.5wt.%. The friction and wear test was performed using four ball tribotester. An experiment on orthogonal cutting process was carried out to evaluate the machining performances in terms of cutting force, cutting temperature, chip thickness and tool-chip contact length. The results reveal that the mixture of 0.05wt.% of hBN particles in the MJO5-based oil (MJO5a) outperformed the SE in terms of friction and wear. MJO5a showed excellent machining performances by reducing the machining force and temperature, which related to the formation of thinner chips and small tool-chip contact length. MJO5a is the best substitute to SE as sustainable MWFs in the machining operation with regards to the environmental and health concern

Minimization of tool path length of drilling process using particle swarm optimization (PSO)

In the era of challenging economic, the industry in our country has been forced to produce a good quality product and increase the productivity of machining process simultaneously in order to compete with other countries. Drrilling process is one of a very important cutting process in industry. In a drilling for machining by Computer Numerical Control (CNC) such as drilling machines, the parameter of the tool routing path for the machining operation plays a very important role to minimize the machining time (Tiwari 2013, Rao and Kalyankar 2012) . This machine can be used with procedures for drilling, spreading, weaning and threading with a lot of the holes precisely. In order to increase the efficiency and productivity of drilling process, optimization on parameters of process can lead to better performance. Optimization of holes drilling operations will lead to reduction in time order and better productivity of manufacturing systems. Optimizing the tool path has played an important role, especially in mass production because reducing the time to produce one piece eventually lead to a significant reduction in the cost of the entire series (Pezer, 2016). In various publications and articles, scientists and researchers adapted several methods of artificial intelligence (AI) or hybrid optimization method for tool path artificial immune system (AIS), genetic algorithms (GA), Artificial Neural networks (ANN) Ant Colony Optimization (ACO) and Particle Swarm Optimization (PSO) (Narooei and Ramli, 2014). These methods were been proven that can produce better performance and increase the productivity of drilling process. Therefore, in this study, the Particle Swarm Optimization (PSO) algorithm was develop in order to minimizing the tool path length in the drilling process which can produce the better results for the required machining time process. For this study, the main purpose is to apply the Particle Swarm Optimization (PSO) algorithm for use in searching for the optimal tool routing path for in simulation of drilling proces

Tribological analyses of modified jatropha oil with hBN and graphene nanoparticles as an alternative lubricant for machining process

The increase of health and environmental consciousness has motivated the effort of technology improvement on lubrication by finding and exploring another potential alternative to replace mineral-based metalworking fluids. Due to this concern, vegetable-based oils have been recognised as an ideal lubricating base oil in machining due to low toxicity, biodegradable, and renewable energy sources. Moreover, nanofluids have attracted enormous attention in the field of lubrication due to excellent physical and chemical properties that can enhance tribological characterisation. The objective of the current work is to develop a new formulation of nanofluids in modified jatropha oil (MJO) by adding hexagonal boron nitride (hBN) and graphene nanoparticle additives at the lowest concentration (0.01, 0.025. and 0.05 wt. %). The physicochemical tests in terms of kinematic viscosity and viscosity index were conducted and compared with synthetic ester (SE). Tribology testing was conducted through four-ball test to determine the coefficient of friction, mean wear scar diameter, and friction torque. The result shows a significant improvement of MJO samples by adding nanoparticle additives compared to the SE. MJOg2 (MJO + 0.025 wt. % of graphene) exhibited excellent tribological behaviour by providing the lowest coefficient of friction and friction torque. Meanwhile, MJOh1 (MJO + 0.01 wt. % of hBN) provided with a smaller mean wear scar diameter among other lubricant samples. Conclusively, the addition of nanoparticle additives significantly enhanced the tribological characteristics and is highly suitable as a substitute for SE

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

Modified Jatropha nano-lubricant as metalworking fluid for machining process

Biodegradable oils that were derived from the nature are renewable sources that may substitute the petroleumbased and synthetic oils. However, the highly viscous Jatropha oil draws upon unsatisfactory lubrication performance in the machining process. Thus, in this study, the chemically modified Jatropha oils with and without the hBN nanoparticles additive were tested on an orthogonal cutting process as a metalworking fluid. The oil viscosity, cutting force (Fc), cutting temperature (Tc) and tool-chip contact length (Lc) are the criteria being evaluated. The results show that MJO+0.05wt.% hBN posed high viscosity index which correlates with the low Fc, Tc and Lc. This increases its potential for implementation as a green metalworking fluid for a sustainable machining process

Performance comparative of modified jatropha based nanofluids in orthogonal cutting process

As machining operation is getting crucial, thus nanotechnology has been considered in providing more effective performance to reduce friction coefficient and wear protection of both workpiece and tool. This study investigated effect of an inclusion of solid nanoparticle additives such hexagonal boron nitride (hBN), graphene, copper oxide (CuO) at 0.05 wt.% concentration in modified jatropha (MJO) based oil. The performance of nanofluids was evaluated by conducting friction and wear test via four-ball test as well as machining process through orthogonal cutting process. The attained results were then compared with synthetic ester. This present study revealed the MJO nanofluids (MJO + 0.05 wt.% hBN, MJO + 0.05 wt.% graphene and MJO + 0.05 wt.% CuO) showed higher lubrication performance as compared to the commercial synthetic ester in term of physical properties and tribological behaviour. This condition resulted in the excellent machining performance which was explained by the reduction in maximum cutting temperature, chip thickness, effect of morphology chip and tool-chip contact length. Therefore, the MJO nanofluids can be considered as a potential sustainable metalworking fluid to replace the usage of the currently used synthetic ester in machining operation

Microstructure analysis of aluminium metal matrix alloy with silicon carbide and hexogonal boron nitride

Aluminum metal matrix composite (AMMCs) are considered a group of new advance material for its light, weight, high strength, modulus, low co-efficient of thermal expansion and good wear properties. In recent years, Metal Matrix Composite (MMCs) have attracted much attention due to excellent mechanical properties such as high specific strength and wear resistance (Poletti et al., 2008). AMMCs are widely used in aircraft, aerospace, automobile and various others field. The MMCs encompasses a wide range scale and microstructure. MMCs could be a material with a least two constituent elements. One necessary to be metal whereas another could also be special metal or alternative material like reinforcement ceramic. Metal matrix composite attract great deal of attentions nowadays due to their great mechanical properties and also their application in advance industry. The network is bulk and nonstop material though support is short and end material improved into matrix. The reinforcement should be stable in given working temperature and non-reactive too. The most commonly used reinforcement are silicon carbide (SiC) and aluminum oxide (Al2O3). The primary function of the reinforcement in MMCs is to carry most of the applied load, where the matrix binds the reinforcement together, and transmit and distributes the external load to the individual reinforcement. Good wetting is an essential condition for the generation for satisfactory bond between particles between particles reinforcement. The composite microstructure may be subdivided, as depicted in, according to whether the reinforcement is in the form of continuous fibers, short fibers or particles

Application of wavelet analysis in tool wear evaluation using image processing method

Tool wear plays a significant role for proper planning and control of machining parameters to maintain the product quality. However, existing tool wear monitoring methods using sensor signals still have limitations. Since the cutting tool operates directly on the work-piece during machining process, the machined surface provides valuable information about the cutting tool condition. Therefore, the objective of present study is to evaluate the tool wear based on the workpiece profile signature by using wavelet analysis. The effect of wavelet families, scale of wavelet and statistical features of the continuous wavelet coefficient on the tool wear is studied. The surface profile of workpiece was captured using a DSLR camera. Invariant moment method was applied to extract the surface profile up to sub-pixel accuracy. The extracted surface profile was analyzed by using continuous wavelet transform (CWT) written in MATLAB. The re-sults showed that average, RMS and peak to valley of CWT coefficients at all scale increased with tool wear. Peak to valley at higher scale is more sensitive to tool wear. Haar was found to be more effective and significant to correlate with tool wear with highest R2 which is 0.9301