International Journal of Mechanical Engineering and Applications
Volume 7, Issue 4, August 2019, Pages: 91-100
Received: May 24, 2019;
Accepted: Aug. 5, 2019;
Published: Aug. 23, 2019
Views 518 Downloads 112
Tran Minh Duc, Department of Manufacturing Engineering, Faculty of Mechanical Engineering, Thai Nguyen University of Technology, Thai Nguyen, Vietnam
Pham Quang Dong, Department of Manufacturing Engineering, Faculty of Mechanical Engineering, Thai Nguyen University of Technology, Thai Nguyen, Vietnam
Tran The Long, Department of Manufacturing Engineering, Faculty of Mechanical Engineering, Thai Nguyen University of Technology, Thai Nguyen, Vietnam
Dang Van Thanh, Faculty of Basic Sciences, College of Medicine and Pharmacy, Thai Nguyen University, Thai Nguyen, Vietnam
The current study demonstrates the effect of minimum quantity cooling lubrication (MQCL) using MoS2 emulsion-based nanofluid on hard milling of SKD tool steel (52-60 HRC) with coated cemented carbide inserts. The input machining parameters including nanoparticle concentration, cutting speed and hardness on cutting forces are investigated in term of cutting force components by using ANOVA analysis applied for the Box-Behnken experimental design. The results indicate that the hardness and nanoparticle concentration have a strongest influence on cutting forces. The interaction effects of investigated parameters are studied in detail and provide the important direction for using MoS2 nanofluid efficiently with the proper concentration of 1.0-1.1 wt%. Moreover, the cutting performance of carbide tools is significant improved during hard milling process due to the better cooling and lubricating effects of MQCL technique.
Tran Minh Duc,
Pham Quang Dong,
Tran The Long,
Dang Van Thanh,
Evaluation of MQCL Technique Using MoS2 Nanofluids During Hard Milling Process of SKD 11 Tool Steel, International Journal of Mechanical Engineering and Applications.
Vol. 7, No. 4,
2019, pp. 91-100.
Feng Gong, Jun Zhao, Yiwei Jiang, Haiwang Tao, Zuoli Li, Jian Zang (2017), “Fatigue failure of coated carbide tool and its influence on cutting performance in face milling SKD11 hardened steel”, Int. Journal of Refractory Metals and Hard Materials, Vol. 64, pp. 27–34.
J. Paulo Davim (2011), “Machining of Hard Materials”, Springer-Verlag London Limited.
C. Y. Wang, Y. X. Xie, Z. Qin, H. S. Lin, Y. H. Yuan, Q. M. Wang (2015), “Wear and breakage of TiAlN- and TiSiN-coated carbide tools during high-speed milling of hardened steel”, Wear, Vols. 336–337, pp. 29-42.
Zhang, K., Deng, J., Meng, R., Gao, P., & Yue, H. (2015). “Effect of nano-scale textures on cutting performance of WC/Co-based Ti55Al45N coated tools in dry cutting”, International Journal of Refractory Metals and Hard Materials, Vol. 51, pp. 35–49. doi: 10. 1016/j. ijrmhm. 2015. 02. 011.
Liu, Y., Deng, J., Wang, W., Duan, R., Meng, R., Ge, D., & Li, X. (2018), “Effect of texture parameters on cutting performance of flank-faced textured carbide tools in dry cutting of green Al2O3 ceramics”, Ceramics International, Vol. 44, Issue 11, pp. 13205–13217. doi: 10. 1016/j. ceramint. 2018. 04. 146.
Liu, Y., Deng, J., Wang, W., Duan, R., Meng, R., Ge, D., & Li, X. (2018), “Effect of texture parameters on cutting performance of flank-faced textured carbide tools in dry cutting of green Al2O3 ceramics”, Ceramics International, 44 (11), 13205–13217. doi: 10. 1016/j. ceramint. 2018. 04. 146.
Kumar, C. S., & Patel, S. K. (2018), “Effect of WEDM surface texturing on Al2O3 /TiCN composite ceramic tools in dry cutting of hardened steel”, Ceramics International, Vol. 44, Issue 2, pp. 2510–2523. doi: 10. 1016/j. ceramint. 2017. 10. 236.
Xing, Y., Deng, J., Zhao, J., Zhang, G., & Zhang, K. (2014), “Cutting performance and wear mechanism of nanoscale and microscale textured Al2O3/TiC ceramic tools in dry cutting of hardened steel”, International Journal of Refractory Metals and Hard Materials, Vol. 43, pp. 46–58. doi: 10. 1016/j. ijrmhm. 2013. 10. 019.
Khaider Bouacha, Mohamed Athmane Yallese, Tarek Mabrouki, Jean-François Rigal (2010), “Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool”, Int. Journal of Refractory Metals & Hard Materials, Vol. 28, pp. 349–361.
M. C. Kang, K. H. Kim, S. H. Shin, S. H. Jang, J. H. Park, C. Kim (2008), “Effect of the minimum quantity lubrication in high-speed end-milling of AISI D2 cold-worked die steel (62 HRC) by coated carbide tools”, Surface & Coatings Technology, Vol. 202, pp. 5621–5624.
Rahim, E. A., & Dorairaju, H. (2018), “Evaluation of mist flow characteristic and performance in Minimum Quantity Lubrication (MQL) machining. Measurement”, Vol. 123, pp. 213–225. doi: 10. 1016/j. measurement. 2018. 03. 015.
Tunc, L. T., Gu, Y., & Burke, M. G. (2016), “Effects of Minimal Quantity Lubrication (MQL) on Surface Integrity in Robotic Milling of Austenitic Stainless Steel”, Procedia CIRP, Vol. 45, pp. 215–218. doi: 10. 1016/j. procir. 2016. 02. 337.
Joshi, K. K., kumar, R., & Anurag. (2018), “An Experimental Investigations in Turning of Incoloy 800 in Dry, MQL and Flood Cooling Conditions”, Procedia Manufacturing, Vol. 20, pp. 350–357. doi: 10. 1016/j. promfg. 2018. 02. 051.
Duc Tran Minh and Long Tran The (2016), “Investigation of MQL-Employed Hard-Milling Process of S60C Steel Using Coated-Cemented Carbide Tools”, Journal of Mechanics Engineering and Automation, Vol. 6, pp. 128-132.
Tran The Long, Tran Minh Duc (2018), “Micro/Nanofluids in Sustainable Machining”, Book tittle: Microfluidics and Nanofluidics, 1st ed.; Editor: Mohsen Sheikholeslami; Publisher: Intech Open, United Kingdom, ISBN 978-1-78923-541-8. Doi: 10. 5772/intechopen. 71136.
Duc Tran Minh, Long Tran The, Ngoc Tran Bao (2017), “Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools”, Advances in Mechanical Engineering, Vol. 9, pp. 1-9. Doi: 10. 1177/1687814017710618.
Pil-Ho Lee, Jung Soo Nam, Chengjun Li and Sang Won Lee (2012), “An Experimental Study on Micro-Grinding Process with Nanofluid Minimum Quantity Lubrication (MQL)”, International Journal of Precision Engineering and Manufacturing, Vol. 13, pp. 331-338. doi: 10. 1007/s12541-012-0042-2.
Uysal, A., Demiren, F., & Altan, E. (2015), “Applying Minimum Quantity Lubrication (MQL) Method on Milling of Martensitic Stainless Steel by Using Nano MoS2 Reinforced Vegetable Cutting Fluid”, Procedia - Social and Behavioral Sciences, Vol. 195, pp. 2742–2747. doi: 10. 1016/j. sbspro. 2015. 06. 384.
Li, B., Li, C., Zhang, Y., Wang, Y., Jia, D., Yang, M., Sun, K. (2017), “Heat transfer performance of MQL grinding with different nanofluids for Ni-based alloys using vegetable oil”, Journal of Cleaner Production, Vol. 154, pp. 1–11. doi: 10. 1016/j. jclepro. 2017. 03. 213.
Yıldırım, Ç. V., Sarıkaya, M., Kıvak, T., & Şirin, Ş. (2019), “The effect of addition of hBN nanoparticles to nanofluid-MQL on tool wear patterns, tool life, roughness and temperature in turning of Ni-based Inconel 625”, Tribology International. doi: 10. 1016/j. triboint. 2019. 02. 027.
M. K. A. Ali, H. Xianjun, L. Mai, C. Qingping, R. F. Turkson, C. Bicheng (2016), “Improving the tribological characteristics of piston ring assembly in automotive engines using Al2O3 and TiO2 nanomaterials as nanolubricant additives”, Tribology International, Vol. 103, pp. 540-554. Doi: 10. 1016/j. triboint. 2016. 08. 011.
Pashmforoush, F., Delir Bagherinia, R. (2018), “Influence of water-based copper nanofluid on wheel loading and surface roughness during grinding of Inconel 738 superalloy”, Journal of Cleaner Production, Vol. 178, pp. 363–372. doi: 10. 1016/j. jclepro. 2018. 01. 003.
Tran Minh Duc, Tran The Long, Tran Quyet Chien (2019), “Performance Evaluation of MQL Parameters Using Al2O3 and MoS2 Nanofluids in Hard Turning 90CrSi Steel”, Lubricants, Vol. 7, Issue 5, pp. 1-17. Doi: 10. 3390/lubricants7050040.
Hegab, H.; Kishawy, H. A.; Umer, U.; Mohany, A. (2019), “A model for machining with nano-additives based minimum quantity lubrication”, Int. J. Adv. Manuf. Technol.. doi: 10. 1007/s00170-019-03294-0.
Hegab, H.; Kishawy, H. (2018), “Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication”, J. Manuf. Mater. Process. Vol. 2, Issue 50. doi: 10. 3390/jmmp2030050.
Hegab, H.; Umer, U.; Soliman, M.; Kishawy, H. A. (2018), “Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718”, Int. J. Adv. Manuf. Technol., Vol. 96, pp. 3449–3458. doi: 10. 1007/s00170-018-1825-0.
Maruda, R. W., Krolczyk, G. M., Feldshtein, E., Pusavec, F., Szydlowski, M., Legutko, S., & Sobczak-Kupiec, A. (2016), “A study on droplets sizes, their distribution and heat exchange for minimum quantity cooling lubrication (MQCL)”, International Journal of Machine Tools and Manufacture, Vol. 100, pp. 81–92. doi: 10. 1016/j. ijmachtools. 2015. 10. 008.
Maruda, R. W., Krolczyk, G. M., Feldshtein, E., Nieslony, P., Tyliszczak, B., & Pusavec, F. (2017), “Tool wear characterizations in finish turning of AISI 1045 carbon steel for MQCL conditions”, Wear, Vols. 372-373, pp. 54–67. doi: 10. 1016/j. wear. 2016. 12. 006.
Maruda, R. W., Krolczyk, G. M., Niesłony, P., Krolczyk, J. B., & Legutko, S. (2016), “Chip Formation Zone Analysis During the Turning of Austenitic Stainless Steel 316L under MQCL Cooling Condition”, Procedia Engineering, Vol. 149, pp. 297–304. doi: 10. 1016/j. proeng. 2016. 06. 670.
S. Pervaiz, I. Deiab, A. Rashid, M. Nicolescu (2017), “Minimal quantity cooling lubrication in turning of Ti6Al4V: Influence on surface roughness, cutting force and tool wear”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 23, Issue 9. Doi: 10. 1177/0954405415599946.
Rahmati, B., Sarhan, A. A. D., & Sayuti, M. (2014), “Morphology of surface generated by end milling AL6061-T6 using molybdenum disulfide (MoS2) nanolubrication in end milling machining”, Journal of Cleaner Production, Vol. 66, pp. 685–691. doi: 10. 1016/j. jclepro. 2013. 10. 048.
Hilsch, Rudolf (1947), “The use of the expansion of gases in a centrifugal field as cooling process”, The Review of Scientific Instruments, Vol. 18, Issue 2, pp. 108–113.
Dong, P. Q., Duc, T. M., Long, T. T. (2019), “Performance Evaluation of MQCL Hard Milling of SKD 11 Tool Steel Using MoS2 Nanofluid”, Metals, Vol. 9, p. 658. Doi: 10. 3390/met9060658.
Dang Van Thanh, Chien-Chung Pan, Chih-Wei Chu and Kung-Hwa Wei (2014), “Production of few-layer MoS2 nanosheets through exfoliation of liquid N2–quenched bulk MoS2”, RSC Adv., Vol. 4, pp. 15586–15589.