role of mql and nano fluids on the machining of nicrofer c263

5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014,
IIT Guwahati, Assam, India
ROLE OF MQL AND NANO FLUIDS ON THE MACHINING OF
NICROFER C263
P Subhash Chandra Bose1*, C S P Rao2, Kishore Jawale3
1
National Institute of Technology, Warangal, 506004, [email protected]
(corresponding author)
2
National Institute of Technology, Warangal, 506004, [email protected]
3
National Institute of Technology, Warangal, 506004, [email protected]
Abstract
Minimum Quantity Lubrication (MQL) is a very good tradeoff between over-use of cutting fluids and poor
surface integrity obtained by dry machining. MQL provides eco friendly machining environment and improves
machinability characteristics. Nanofluids have novel properties that make them potentially useful in heat
transfer medium in cutting zone. This paper presents the effect of MQL and Nanofluids with 1% volume of
Al2O3 and 4% volume Al2O3 on the machinability characteristics of Nicrofer C263 mainly with respect to
Surface Roughness, Cutting Forces and Temperature dissipation. Experimental analysis for three different
conditions – dry, MQL and MQL + Al2O3 Nanoparticles are carried out. It was found that use of combination of
Nanofluids and MQL gives better surface finish with good temperature dissipation in cutting zone when
compared with other conditions. It is also observed that there is a decrease in cutting forces and which may lead
to reduced tool wear.
Keyword: Nano Fluids, MQL, Super alloys, machining.
Research by Rao DN, Srikant RR (2006) showed
straight oil is not intended to be mixed with water.
1 Introduction
Emulsions
possess
excellent
heat
transfer
The objective of any machining operations is characteristics because of their high water content.
primarily to obtain lower machining costs, improving Straight oils excel when a high degree of lubricity is
quality of product and increasing productivity. This required. Both media guarantee efficient chip
objective can be achieved by machiningat the highest transport, when compressed air is used instead of a
cutting speed with maximum tool life and least cooling lubricant, the lubrication benefit of the fluid is
discards. Somemachining operations can be carried lost. The coolant effect is much less pronounced than
out “dry”, but cutting fluids have been with water or oil. Water and oil are also superior to air
usedextensively and play a significant role in in terms of chip transport characteristics. In wet
machining areas. EmelKuram, et al. (2013) state that machining, machining with cutting fluids causes
cutting fluids affect theproductivity of machining environment, water source pollution and soil become
operations, tool life, and quality of workpiece and polluted during disposal of the cutting fluid.
preventthe cutting tool and machine from overheating
In MQL operations, the media used is
as well.
generally straight oil, but some applications have also
Dry machining means that no cutting fluid is utilized an emulsion or water as showed by M. N.
used during process. For economicas well as Morgan (2012). These fluid media is fed to the tool
environmental reasons machining process is carried and work piece interface in tiny quantities. This is
out without any cuttingfluid but dry machining has done with or without the assistance of a transport
some disadvantages. During dry machining medium, e.g., air. In many machining operations,
process,temperature of the cutting tool is very high minimum quantity cooling lubrication (MQL) is the
and this induces excessive toolwear thus decreasing key to successful dry machining.
tool life. Also the chips generated at machining cannot
Nanofluids
are
engineered
colloidal
washaway and these chips cause deterioration on the suspensions of Nanoparticles in a base fluid. It has
machined surface.
been found by M. M. A. Khan (2009), that Nanofluids
The primary function of a cutting fluid in wet have much higher and strongly temperature dependent
machining operations is to cool, to lubricate, and thermal conductivity at very low particle
toremove the chips. Emulsions or straight oils are concentration, which is considered to be a key
generally used depending on the manufacturing parameter for enhanced performance for many of the
operation and machining task involved. Straight oil is applications. Al2O3 Nanoparticles have been
a cutting fluid that is composed of mineral oil or analyzedby Pil-Ho Lee (2012) and it was found to be
vegetable oil and is mainly used as a lubricant.
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ROLE OF MQL AND NANO FLUIDS ON THE MACHINING OF NICROFER C263
most suitable as it increases wettability, reduces
cutting forces, and shows enhanced tribological
effects (like ball / roller effect) along with minimum
toxic nature.
2 Experimental Procedure
2.1 Work piece
Nicrofer C263 is a Nickel – Chromium alloy
with chemical composition as shown in Table 1.
Table 1: Chemical Composition.
Ni
78.8%
Cr
20%
Ti
0.39%
Mn
0.1%
Si
0.7%
C
0.01%
Multi-layered
PVD
(Physical
Vapor
Deposition) coated cemented tungsten carbide inserts
are used for the turning tests. These inserts are
manufactured by Widia. The coated carbide grade was
TN6025, which is designed for light and medium
turning operations of high temperature alloys.
TN6025 inserts are Nano-multi layered TiAlN coated
insert, which has a very high wear resistance and good
toughness.
2.2 Machine Tool
Experiments have been carried out by plain
turning on Nicrofer C263 alloy on retrofitted VDF
CNC
lathe.VDF
is
an
acronym
forVereinigteDrehbank-Fabriken which translates
basicallyto: Combined Lathe Makers.The ranges of
the cutting velocity, feed rate and depth of cut were
selected based on the tool manufacturer’s
recommendation and industrial practices as shown in
Table 2.
Table 2: Experimental Conditions
Machine tool: Retrofitted VDF CNC lathe
Work pieces
Cutting tool
Insert code system
Cutting velocity, Vc
Feed rate, f:
Depth of cut,d:
MQL supply:
Environment:
Measurement of
surface roughness
Measurement of
cutting forces
Measurement of
cutting temperature
Nicrofer C263(42.18 X 250 of 4
rods)
Multi-layered PVD coated
cemented tungsten carbide
inserts
TNMG16040822
30 - 55 m/min
0.08 - 0. 2 mm/rev
0.5 - 1.5mm
Air:5 bar, Lubricant: 60 ml/h
Dry, MQL and MQL with Nano
fluids.
Handy surf
Kistler Dynamometer
INFRARED THERMOMETER
2.3 Cutting Fluid
Here Vegetable Oil {Max mix ST-2020}, is
used as cutting fluid in MQL condition and hereafter
it is called as MQL. Max Mist ST-2020 is an
environmentally acceptable vegetables oil based
lubricant. Max mist ST-2020 will yield the lowest net
manufacturing costs of any fluid as found byJung Soo,
et al. (2011.)
2.4 Preparation of Nano fluids
In this work the alumina (Al2O3) Nano
particles are mixed with vegetable oil, as a base fluid
to make Al2O3Nanofluid. Nano Al2O3 particles are
selected due to their superior tribological and antitoxic properties based on study of Pil-Ho Lee, et al.
(2012). The method used to make Nano fluid is given
below. Take one gram of Al2O3 Nano particles and
directly mix with 100 ml vegetable oil as a base fluid
and prepare the sample.1Vol% of Al2O3 Nano fluid =
100 ml of vegetable oil + 1gm of Al2O3 Nano
particles. 4Vol% of Al2O3 Nano fluid = 100 ml of
vegetable oil + 4gm of Al2O3 Nano particles. The
above composition has to be mixed continuously
about 8 to 9 hours using Magnetic stirrer. The size of
Al2O3 particles is about 5 Nm. Here after Nano fluid
means a mix of MQL and Al2O3 particles.
2.5 Selection of Cutting Parameters
The Experimental Design was done using
Central Composite Design using Design Expert
Software. The optimization was performed using
Response Surface methodology. The initial values of
each process parameter are selected according to the
Tool Manufacturers specifications and ASME
handbook standards, mentioned in Appendix.
Optimum machining Parameters for Nicrofer C263 by
using Response surface Methodology are shown in
Table 3.
Table 3: Optimum parameters for Nicrofer C263
Feed
Depth
Optimum
Speed
Nicrofer C263
Value
mm/min mm/rev of cut
Surface
0.12
0.75
0.829
42.74
Roughness Ra
0.09
0.9
Cutting Forces 136.716
54.75
Cutting Temp.
0.09
0.9
98
36
°C
3 Effects of MQL and Nanofluids
Three optimum conditions obtained by RSM
(Response Surface Methodology) has been selected to
explore the role of MQL (Vegetable Oil) and MQL +
Nano fluid (1% Al2O3 and 4%Al2O3) on the
machinability characteristics of work material mainly
in terms of Surface roughness, Cutting Temperature
and Cutting Force. The observations for machining
Nicrofer under different cutting fluid conditions are
tabulated in Table 4.
363-2
5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014,
IIT Guwahati, Assam, India
Table 4:: Experimental values of surface roughness, cutting forces and cutting
cutting temperature of Nicrofer
C263
263 under dry, MQL and Nano fluid conditions
Nanofluid+MQ
L
(4% Al2O3)
Nanofluid+MQ
L (1% Al2O3)
Mist
coolant+MQL
Dry condition
Run
No.
Speed
m/min
Feed
mm/rev
Depth
of cut
Ra1
Ra2
Ra3
Avg. Ra
micron
Force
Newton
Temp.
°
C
1
42.74
0.12
0.75
0.54
0.51
0.52
0.5233
163
65.2
2
54.75
0.09
0.9
0.52
0.48
0.49
0.4966
149
70.4
3
36
0.09
0.9
0.4
0.37 0.38
0.3833
194
72.9
1
42.74
0.12
0.75
0.65
0.66
0.68
0.6633
175
66.9
2
54.75
0.09
0.9
0.5
0.64
0.7
0.6133
161
72.8
3
36
0.09
0.9
0.6
0.52
0.54
0.476
216
74.6
1
42.74
0.12
0.75
0.69
0.62
0.69
0.666
252.8
99.1
2
54.75
0.09
0.9
0.62
0.75
0.73
0.70
191.8
76.8
3
36
0.09
0.9
0.51
0.48
0.53
0.5066
216.7
77.1
1
42.74
0.12
0.75
0.72
0.98
1.17
0.956
261
112.3
2
54.75
0.09
0.9
0.99
0.95
0.84
0.926
232
121.9
3
36
0.09
0.9
0.99
1.03
1.04
1.02
234
79.2
3.1 Surface Roughness
It is observed that plain MQL condition gives
better surface finish than the dry cutting process,
which may be due to controlled deterioration of the
auxiliary cutting edge caused by abrasion, chipping
and built up edge formation. It is also observed that
Nanofluid further decreases the surface roughness,
this is because Nanofluids exhibit enhanced thermal
properties such as higher thermal conductivity and
heat transfer coefficients compared with plain MQL.
Increasing concentration of Al2O3 from 1% to 4% still
st
further enhances surface integrity.
Figure 1depicts
depicts surface roughness v/s speed,
feed and depth of cut in all the three environment
conditions i.e. Dry, MQL and Nano fluid, it is clear
from the Figures that the range of the surface
roughness is gradually decreasing from dry to MQL
and MQL to Nano fluid
id as shown in following Table
5.
Figure 1:: Ra v/s experimental runs
Table 5:: Surface Roughness Reduction
Range of
Surface
roughness
% of reduction
Dry condition
0.92 to 1.02 µm
-
MQL
0.5 to 0.7 µm
31 – 38 %
(1% Al2O3)Nano
Fluid
0.47 to 0.66 µm
6 – 12 %
(4% Al2O3)Nano
Fluid
0.38 to 0.52µm
21 – 23 %
3.2 Cutting Forces
Figure 2 for optimum Cutting Force v/s
Speed, Feed and Depth of Cut
ut conditions in all the
four environments i.e. Dry, MQL and Nano fluid, it is
clear that the range of the Cutting Force is gradually
decreasing from dry to MQL and from MQL to Nano
fluid is shown in Table 6.
This reduction of cutting forces from dry
condition to MQL may be due to change in the chip
tool interaction and retention of cutting edge
sharpness due to reduction of cutting temperature. It is
observed that there is a reduction ofcutting
cutting forces in
Nano fluid conditions as compared to dry and MQL,
this may be due to reduction of cutting zone
temperatures, whichh results in less friction and a
decrease in the formation of built up edges.
363-3
ROLE OF MQL AND NANO FLUIDS ON THE MACHINING OF NICROFER C263
4 Conclusions
Based on the experimental
conclusions are drawn:
Figure 2: Fz v/s experimental runs
Table 6:: Cutting Forces Reduction
Range of
Cutting forces
% of reduction
Dry condition
232 to 261 N
-
MQL
191.8 to 252.8 N
3 to 17 %
161 to 216 N
14 to 16 %
149 to 194 N
7 to 10 %
(1%
Al2O3)Nano
Fluid
(4%
Al2O3)Nano
Fluid
3.3 Cutting Temperature
The Figures 3 depicts optimum Cutting
Temperature v/s Speed, Feed and Depth of cut
conditions in all the three environments i.e. Dry, MQL
and Nano fluid. It is clear that the range of the
Temperature is gradually decreasing from dry to Nano
fluid is shown in Table 7.
results,
following
1. There is a reduction of 31 to 38% in surface
roughness using MQL compared to dry
machining.Use of (1% Al2O3) Nano fluids still
further reduces surface roughness value by 6 to 12
%, compared to MQL. (4% Al2O3) Nanofluids
reduces surface roughness by 21 to 23 %
compared to (1% Al2O3) Nano fluids
fluids.
2. Use of MQL reduces cutting forces by 3 to 17 %
when compared with Dry machining. There is a
further reduction off 14 to 16 % in cutting forces
when (1% Al2O3) Nano fluids are used. (4%
Al2O3) Nano fluid reduces Cutting forces by 7 to
10 % compared to (1% Al2O3) Nano fluids.
fluids
3. MQL condition reduces cutting zone temperature
by 3 to 18 %. Implementation of Nano fluids st
still
reduces this cutting temperature by 13 to 24 %.
(4% Al2O3) Nano fluids reduce cutting
temperature by 2 to 3 % compared to (1% Al2O3)
Nano fluids.
These experiments show that Surface Roughness,
Cutting Forces and Temperature can be reduced
significantly by machining Nicrofer C263 using Nano
fluid (i.e. 1Vol% of Al2O3 Nano fluid)) as compared to
Dry and MQL.
Acknowledgement
This paper is partly supported by DRDL Hyderabad.
Material was being supplied by DRDL and
experiments were conducted in PE Lab of NIT
Warangal.
Appendix
Table 8: Levels for Nicrofer C263
263 according to
ASME and Tool Manufacturer Guide
High
Low
Centre
Nicrofer C263
level
Level
42.5
55
Speed (mm/min)
30
0.14
0.2
Feed (mm/rev)
0.08
1
1.5
Depth of Cut (mm)
0.5
Figure 3: CT v/s experimental runs
Table 7: Temperature Reduction
Range of
Temperature
% of
reduction
Dry condition
79.2º C – 121.9º C
-
MQL
77.1º C – 99.1º C
3 – 18 %
66.9º C – 74.6º C
13 – 24 %
65.2 – 72.9º C
2–3%
(1% Al2O3)Nano
Fluid
(4% Al2O3)Nano
Fluid
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363-4
5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014,
IIT Guwahati, Assam, India
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