BibTex RIS Cite

Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel

Year 2007, Volume: 20 Issue: 2, 23 - 32, 25.03.2010

Abstract

In all machining processes, tool wear is a natural phenomenon and it leads to tool failure. The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Metal cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions but the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. The use of cutting fluid generally causes economy of tools and it becomes easier to keep tight tolerances and to maintain workpiece surface properties without damages. Due to these problems, some alternatives has been sought to minimize or even avoid the use of cutting fluid in machining operations. Some of these alternatives are dry machining and machining with minimum quantity lubrication (MQL). This paper deals with the experimental investigation on the role of MQL on cutting temperature, tool wear, surface roughness and dimensional deviation in turning of AISI-4340 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in tool wear rate, dimensional inaccuracy and surface roughness by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.

 Key Words: MQL, tool wear, surface roughness and dimensional deviation

 

References

  • P. Leskover and J. Grum, The metallurgical aspect of machining, Annals of CIRP,35 (1): 537–550 (1986).
  • H. K. Tonshoff and E. Brinkomeier, Determination of the mechanical and thermal influences on machined surface by microhardness and residual stress analysis, Annals of. CIRP,29 (2): 519–532 (1986).
  • M. C. Shaw, J. D. Piggtt and L.P. Richardson, Effect of cutting fluid upon chip–tool interface temperature, Trans. ASME, 71: 45–56 (1951).
  • S. Paul, N. R. Dhar and A. B. Chattopadhyay, Beneficial effects of cryogenic cooling over dry and wet machining on tool wear and surface finish in turning AISI 1060 steel, Proc. of the ICAMT-2000, UTM, Malaysia, 209-214 (2000).
  • C. Cassin and G. Boothroyd, Lubrication action of cutting fluids, J. Mech. Eng. Science. 7 (1): 67–81 (1965).
  • M. Mazurkiewicz, Z. Kubala and J. Chow, Metal machining with high pressure water-jet cooling assistance-A new possibility, J. Eng. Ind. 111: 7–12 (1989).
  • A. Alexander, A. S. Varadarajan and P. K. Philip, Hard turning with minimum cutting fluid: A viable green alternative on the shop floor, Proc. of the 18th AIMTDR, 152–155 (1998).
  • M. Sokovic and K. Mijanovic, Ecological aspects of the cutting fluids and its influence on quantifiable parameters of the cutting processes, JMPT, 109 (1-2): 181-189 (2001).
  • F. Klocke and G. Eisennbla¨tter, Dry cutting, CIRP, 46 (2): 519-526 (1997).
  • G. Byrne and E. Scholta, Environmentally clean machining processes-A strategic approach, CIRP, 42(1): 471-474 (1993).
  • Klocke, F. and Eisenblatter, G., Coated tools for metal cutting-features and applications, CIRP, 48(2): 515-525 (1999).
  • Heisel, U. and Lutz, M., Application of minimum quantity cooling lubrication technology in cutting processes, Prod. Engineering, II(1): 49-54 (1994).
  • Wakabayashi, T., Turning using extremely small amount of cutting fluids, JSME, 41/1: 143-148 (1998).
  • J. W. Sutherland, et al., An experimental investigation of air quality in wet and dry turning, Annals of CIRP, 49/1: 61-64 (2000).
  • S. Suda, et al., Evaluation of machinability with MQL system and effectiveness in production lines, Proc. of the Int. Tribology Conf., Nagasaki, 203-208 (2001).
  • J. McCabe and M. A. Ostaraff, Performance experience with near-dry machining of aluminum, Lubr. Eng., p. 22-27 (2001).
  • T. F. MaClure, R. Adams and M. D. Gugger, Comparison of flood vs. microlubrication on machining performance, Internet: http://www.unist.com/ techsolve.html
  • H. K. Tönshoff and W. Spintig, Machining of holes developments in drilling technology, CIRP, 551-561 (1994).
  • E. Lugscheider, O. Knotek, C. Barimani, T. Leyendecker, O. Lemmer and R. Wenke, Investigations on hard coated reamers in different lubricant free cutting operations, Surface and Coatings Technology, 90: 172177 (1997).
  • N. R. Dhar, M. W. Islam, S. Islam and M. A. H. Mithu, The influence of minimum quantity of lubrication (MQL) on cutting temperature, chip and dimensional accuracy in turning AISI-1040 steel, Journal of Material Processing Technology, 171: 93-99 (2006).
  • V. Derflinger, H. Brä;ndle and H. Zimmermann, New hard/ lubricant coating for dry machining, Surface Coating Technology, 113: 286-292 (1996).
  • D. U. Braga, A. E. Diniz, G. Miranda and N. L. Coppini, Minimal lubrication in the drilling process of aluminum-silicon alloy-A356 (SAE 323), Proc. of the 3rd Int. Machining and Grinding Conf. (SME), Cincinnati, USA, 1: 683-697 (1999).
  • K. M. Rahman, Effect of minimum quantity lubrication (MQL) in drilling commercially used steels, M. Engg. Dissertation, BUET, Dhaka, Bangladesh (2004).
  • N. R. Dhar and S. Islam, Improvement in machinability characteristics and working environment by minimum quantity lubrication, CASR Project, BUET (2005).
Year 2007, Volume: 20 Issue: 2, 23 - 32, 25.03.2010

Abstract

References

  • P. Leskover and J. Grum, The metallurgical aspect of machining, Annals of CIRP,35 (1): 537–550 (1986).
  • H. K. Tonshoff and E. Brinkomeier, Determination of the mechanical and thermal influences on machined surface by microhardness and residual stress analysis, Annals of. CIRP,29 (2): 519–532 (1986).
  • M. C. Shaw, J. D. Piggtt and L.P. Richardson, Effect of cutting fluid upon chip–tool interface temperature, Trans. ASME, 71: 45–56 (1951).
  • S. Paul, N. R. Dhar and A. B. Chattopadhyay, Beneficial effects of cryogenic cooling over dry and wet machining on tool wear and surface finish in turning AISI 1060 steel, Proc. of the ICAMT-2000, UTM, Malaysia, 209-214 (2000).
  • C. Cassin and G. Boothroyd, Lubrication action of cutting fluids, J. Mech. Eng. Science. 7 (1): 67–81 (1965).
  • M. Mazurkiewicz, Z. Kubala and J. Chow, Metal machining with high pressure water-jet cooling assistance-A new possibility, J. Eng. Ind. 111: 7–12 (1989).
  • A. Alexander, A. S. Varadarajan and P. K. Philip, Hard turning with minimum cutting fluid: A viable green alternative on the shop floor, Proc. of the 18th AIMTDR, 152–155 (1998).
  • M. Sokovic and K. Mijanovic, Ecological aspects of the cutting fluids and its influence on quantifiable parameters of the cutting processes, JMPT, 109 (1-2): 181-189 (2001).
  • F. Klocke and G. Eisennbla¨tter, Dry cutting, CIRP, 46 (2): 519-526 (1997).
  • G. Byrne and E. Scholta, Environmentally clean machining processes-A strategic approach, CIRP, 42(1): 471-474 (1993).
  • Klocke, F. and Eisenblatter, G., Coated tools for metal cutting-features and applications, CIRP, 48(2): 515-525 (1999).
  • Heisel, U. and Lutz, M., Application of minimum quantity cooling lubrication technology in cutting processes, Prod. Engineering, II(1): 49-54 (1994).
  • Wakabayashi, T., Turning using extremely small amount of cutting fluids, JSME, 41/1: 143-148 (1998).
  • J. W. Sutherland, et al., An experimental investigation of air quality in wet and dry turning, Annals of CIRP, 49/1: 61-64 (2000).
  • S. Suda, et al., Evaluation of machinability with MQL system and effectiveness in production lines, Proc. of the Int. Tribology Conf., Nagasaki, 203-208 (2001).
  • J. McCabe and M. A. Ostaraff, Performance experience with near-dry machining of aluminum, Lubr. Eng., p. 22-27 (2001).
  • T. F. MaClure, R. Adams and M. D. Gugger, Comparison of flood vs. microlubrication on machining performance, Internet: http://www.unist.com/ techsolve.html
  • H. K. Tönshoff and W. Spintig, Machining of holes developments in drilling technology, CIRP, 551-561 (1994).
  • E. Lugscheider, O. Knotek, C. Barimani, T. Leyendecker, O. Lemmer and R. Wenke, Investigations on hard coated reamers in different lubricant free cutting operations, Surface and Coatings Technology, 90: 172177 (1997).
  • N. R. Dhar, M. W. Islam, S. Islam and M. A. H. Mithu, The influence of minimum quantity of lubrication (MQL) on cutting temperature, chip and dimensional accuracy in turning AISI-1040 steel, Journal of Material Processing Technology, 171: 93-99 (2006).
  • V. Derflinger, H. Brä;ndle and H. Zimmermann, New hard/ lubricant coating for dry machining, Surface Coating Technology, 113: 286-292 (1996).
  • D. U. Braga, A. E. Diniz, G. Miranda and N. L. Coppini, Minimal lubrication in the drilling process of aluminum-silicon alloy-A356 (SAE 323), Proc. of the 3rd Int. Machining and Grinding Conf. (SME), Cincinnati, USA, 1: 683-697 (1999).
  • K. M. Rahman, Effect of minimum quantity lubrication (MQL) in drilling commercially used steels, M. Engg. Dissertation, BUET, Dhaka, Bangladesh (2004).
  • N. R. Dhar and S. Islam, Improvement in machinability characteristics and working environment by minimum quantity lubrication, CASR Project, BUET (2005).
There are 24 citations in total.

Details

Primary Language English
Journal Section Mechanical Engineering
Authors

Nikhil Dhar

Sumaiya Islam This is me

Mohammad Kamruzzaman This is me

Publication Date March 25, 2010
Published in Issue Year 2007 Volume: 20 Issue: 2

Cite

APA Dhar, N., Islam, S., & Kamruzzaman, M. (2010). Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel. Gazi University Journal of Science, 20(2), 23-32.
AMA Dhar N, Islam S, Kamruzzaman M. Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel. Gazi University Journal of Science. March 2010;20(2):23-32.
Chicago Dhar, Nikhil, Sumaiya Islam, and Mohammad Kamruzzaman. “Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel”. Gazi University Journal of Science 20, no. 2 (March 2010): 23-32.
EndNote Dhar N, Islam S, Kamruzzaman M (March 1, 2010) Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel. Gazi University Journal of Science 20 2 23–32.
IEEE N. Dhar, S. Islam, and M. Kamruzzaman, “Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel”, Gazi University Journal of Science, vol. 20, no. 2, pp. 23–32, 2010.
ISNAD Dhar, Nikhil et al. “Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel”. Gazi University Journal of Science 20/2 (March 2010), 23-32.
JAMA Dhar N, Islam S, Kamruzzaman M. Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel. Gazi University Journal of Science. 2010;20:23–32.
MLA Dhar, Nikhil et al. “Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel”. Gazi University Journal of Science, vol. 20, no. 2, 2010, pp. 23-32.
Vancouver Dhar N, Islam S, Kamruzzaman M. Effect of Minimum Quantity Lubrication (MQL) on Tool Wear, Surface Roughness and Dimensional Deviation in Turning AISI-4340 Steel. Gazi University Journal of Science. 2010;20(2):23-32.