Performance evaluation of aluminium oxide nano particles in cutting fluid with minimum quantity lubrication technique in turning of hardened AISI 4340 alloy steel

Document Type : Article

Authors

1 Department of Industrial Design, National Institute of Technology, Rourkela 769008, Odisha, India

2 Department of Mechanical Engineering, National Institute of Technology, Rourkela 769008, Odisha, India

3 Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India

Abstract

The current research comprises various machinability aspects of 4340 hardened alloy steel which are scrutinized with in context of improvements in main cutting force, tool flank wear, crater wear, surface roughness, microhardness, machined surface morphology, chip morphology, chip reduction coefficient and apparent coefficient of friction under three different cutting fluid applications i.e. compressed air, water soluble coolant based MQL, and nanofluid (using eco-friendly radiator coolant as the base fluid and Al2O3 as the nanoparticle) based MQL technique using cermet cutting inserts and a comparative assessment was performed to select which fluid performed better in terms of various machining attributes among three cutting fluids. The minimum quantity lubrication technique was used in which a smaller volume of coolant sprinkled at high pressure. This method is found as the most effective alternative to minimize health risks and machining costs, which is quite high in other setups. The test specimen was machined at three different cutting speeds i.e. 100,120 and 140m/min along with two machining parameters i.e. feed and depth of cut were kept constant respectively at 0.2mm/rev and 0.4mm. Outcomes made a conclusion that Al2O3 enriched ecofriendly nano-coolant outperformed both compressed air and water soluble coolant in terms of every machinability aspects.

Keywords

Main Subjects


References
1. Rao, R.V. and Kalyankar, V.D. Multi-pass turning
process parameter optimization using teachinglearning-
based optimization algorithm", Scientia Iranica,
E, 20(3), pp. 967{974 (2013).
2. Shen, B., Shih, A.J., and Tung, S.C. Application of
nano
uids in minimum quantity lubrication grinding",
Tribology Transactions, 51(6), pp. 730{737 (2008).
A. Das et al./Scientia Iranica, Transactions B: Mechanical Engineering 27 (2020) 2838{2852 2851
3. Hegab, H., Umer, U., Soliman, M., and Kishawy, H.A.
E ects of nano-cutting
uids on tool performance
and chip morphology during machining Inconel 718",
The International Journal of Advanced Manufacturing
Technology, 96(9{12), pp. 3449{3458 (2018).
4. Kuzu, A.T., Bijanzad, A., and Bakkal, M. Experimental
investigations of machinability in the turning of
compacted graphite iron using minimum quantity lubrication",
Machining Science and Technology, 19(4),
pp. 559{576 (2015).
5. Amini, S., Khakbaz, H., and Barani, A. Improvement
of near-dry machining and its e ect on tool wear in
turning of AISI 4142", Materials and Manufacturing
Processes, 30(2), pp. 241{247 (2014).
6. Kumar, R., Sahoo, A.K., Mishra, P.C., and Das,
R.K. Measurement and machinability study under
environmentally conscious spray impingement cooling
assisted machining", Measurement, 135, pp. 913{927
(2019).
7. Mia, M., Gupta, M.K., Singh, G., Krolczyk, G., and
Pimenov, D.Y. An approach to cleaner production
for machining hardened steel using di erent coolinglubrication
conditions", Journal of Cleaner Production,
187, pp. 1069{1081 (2018).
8. Mia, M., Rifat, A., Tanvir, M.F., Gupta, M.K.,
Hossain, M.J., and Goswami, A. Multi-objective
optimization of chip-tool interaction parameters using
Grey-Taguchi method in MQL-assisted turning", Measurement,
129, pp. 156{166 (2018).
9. Mia, M., Morshed, M.S., Kharshiduzzaman, M., Razi,
M.H., Mostafa, M.R., Rahman, S.M.S., Ahmada, I.,
Ha z, M.T., and Kamal, A.M. Prediction and optimization
of surface roughness in minimum quantity
coolant lubrication applied turning of high hardness
steel", Measurement, 118, pp. 43{51 (2018).
10. Nemati, H., Farhadi, M., Sedighi, K., Ashorynejad,
H.R., and Fattahi, E. Magnetic eld e ects on natural
convection
ow of nano
uid in a rectangular cavity
using the lattice Boltzmann model", Scientia Iranica,
19(2), pp. 303{310 (2012).
11. Amrita, M., Srikant, R.R., and Sitaramaraju, A.V.
Performance evaluation of nanographite-based cutting

uid in machining process", Materials and Manufacturing
Processes, 29(5), pp. 600{605 (2014).
12. Sharma, A.K., Tiwari, A.K., and Dixit, A.R. Progress
of nano
uid application in machining: A review",
Materials and Manufacturing Processes, 30(7), pp.
813{828 (2014).
13. Sharma, P., Sidhu, B.S., and Sharma, J. Investigation
of e ects of nano
uids on turning of AISI D2 steel using
minimum quantity lubrication", Journal of Cleaner
Production, 108, pp. 72{79 (2015).
14. Su, Y., Gong, L., Li, B., Liu, Z., and Chen, D. Performance
evaluation of nano
uid MQL with vegetablebased
oil and ester oil as base
uids in turning",
The International Journal of Advanced Manufacturing
Technology, 83(9{12), pp. 2083{2089 (2015).
15. Patole, P.B. and Kulkarni, V.V. Experimental investigation
and optimization of cutting parameters with
multi response characteristics in MQL turning of AISI
4340 using nano
uid", Cogent Engineering, 4(1), pp.
1{14 (2017).
16. Khajehzadeh, M., Moradpour, J., and Razfar, M.R.
In
uence of nano
uids application on contact length
during hard turning", Materials and Manufacturing
Processes, 34(1), pp. 30{38 (2019).
17. Amrita, M., Shariq, S.A., Manoj, and Gopal, C. Experimental
investigation on application of emulsi er oil
based nano cutting
uids in metal cutting process",
Procedia Engineering, 97, pp. 115{124 (2014).
18. Sharma, A.K., Singh, R.K., Dixit, A.R., and Tiwari,
A.K. Novel uses of alumina-MoS2 hybrid nanoparticle
enriched cutting
uid in hard turning of AISI 304
steel", Journal of Manufacturing Processes, 30, pp.
467{482 (2017).
19. Singh, R.K., Sharma, A.K., Dixit, A.R., Tiwari,
A.K., Pramanik, A., and Mandal, A. Performance
evaluation of alumina-graphene hybrid nano-cutting

uid in hard turning", Journal of Cleaner Production,
162, pp. 830{845 (2017).
20. Kumar, R., Sahoo, A.K., Mishra, P.C., and Das, R.K.
Comparative investigation towards machinability improvement
in hard turning using coated and uncoated
carbide inserts: Part I: Experimental investigation",
Advances in Manufacturing, 6(1), pp. 52{70 (2018).
21. Rahmati, B., Sarhan, A.A.D., and Sayuti, M. Investigating
the optimum molybdenum disul de (MoS2)
nanolubrication parameters in CNC milling of AL6061-
T6 alloy", The International Journal of Advanced
Manufacturing Technology, 70(5{8), pp. 1143{1155
(2013).
22. Saravanakumar, N., Prabu, L., Karthik, M., and
Rajamanickam, A. Experimental analysis on cutting

uid dispersed with silver nano particles", Journal of
Mechanical Science and Technology, 28(2), pp. 645{
651 (2014).
23. Das, S.R., Panda, A., and Dhupal, D. Experimental
investigation of surface roughness,
ank wear, chip
morphology and cost estimation during machining of
hardened AISI 4340 steel with coated carbide insert",
Mechanics of Advanced Materials and Modern Processes,
3(1), pp. 1{14 (2017).
24. Khalilpourazary, S. and Meshkat, S.S. Investigation
of the e ects of alumina nanoparticles on spur gear surface
roughness and hob tool wear in hobbing process",
The International Journal of Advanced Manufacturing
Technology, 71(9{12), pp. 1599{1610 (2014).