Assessment of the effect of borax and boric acid additives in cutting fluids on milling of AISI O2 using MQL system

ORIGINAL ARTICLE
First Online:
Received:
Accepted:
  • 102 Downloads

Abstract

The present study assesses the effects of eco-friendly cutting fluids prepared on cutting performance and tool wear in hard milling of AISI O2 cold work tool steel applying the minimum quantity lubrication (MQL) technique for sustainable manufacturing. Boron compounds such as boric acid (BA) (5% wt.) and borax (BX) (5% wt.) as additives were added to ethylene glycol (EG) of base fluid. For the purpose of comparison, commercial boron oil was utilized in addition to the dry machining as a benchmark using MQL method. The lowest surface roughness value (0.411 μm) was reached in the cutting fluid containing BA. Compared with the dry condition, the surface roughness value was determined to be improved as 52 and 38% in cutting fluids containing BA and BX, respectively. The highest tool life was measured as a cutting length of 3.15 m in the cutting fluid containing BX. According to the experimental results, a raise of tool life occurred in cutting fluids prepared using both BA and BX. Compared with dry condition, tool life was increased by 110% with cutting fluid prepared by BA and by 50% by cutting fluid prepared by BX. The cutting forces decreased with cutting fluids containing both boron compounds. After milling process, the wear type and mechanism of the cutting tool were analyzed by scanning electron microscopy (SEM) aided with energy dispersive spectroscopy (EDS). Furthermore, it has been found that the diffusion and abrasion are dominant wear mechanisms on cutting tools, all the cutting fluids studied. Consequently, the promising results were obtained by adding boron compounds, which are harmless and non-toxic to human and environmental health, to cutting fluid-based EG for improving machinability of AISI O2 cold work tool steel.

Keywords

Minimum quantity lubrication Hardmilling Boric acid Borax AISI O2 Tool wear Cutting performance 
This is a preview of subscription content, log in to check access.

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Krolczyk GM, Nieslony P, Maruda RW, Wojciechowski S (2017) Dry cutting effect in turning of a duplex stainless steel as a key factor in clean production. J Clean Prod 142:3343–3354.  https://doi.org/10.1016/j.jclepro.2016.10.136 CrossRefGoogle Scholar
  2. 2.
    Boswell B, Islam MN, Davies IJ et al (2017) A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining. Int J Adv Manuf Technol:1–20.  https://doi.org/10.1007/s00170-017-0142-3
  3. 3.
    Sharma AK, Tiwari AK, Dixit AR (2016) Effects of minimum quantity lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: a comprehensive review. J Clean Prod 127:1–18.  https://doi.org/10.1016/j.jclepro.2016.03.146 CrossRefGoogle Scholar
  4. 4.
    Guo S, Li C, Zhang Y et al (2017) Experimental evaluation of the lubrication performance of mixtures of castor oil with other vegetable oils in MQL grinding of nickel-based alloy. J Clean Prod 140:1060–1076.  https://doi.org/10.1016/j.jclepro.2016.10.073 CrossRefGoogle Scholar
  5. 5.
    Caliiskan H, Kurbanolu C, Panjan P et al (2013) Wear behavior and cutting performance of nanostructured hard coatings on cemented carbide cutting tools in hard milling. Tribol Int 62:215–222.  https://doi.org/10.1016/j.triboint.2013.02.035 CrossRefGoogle Scholar
  6. 6.
    Zhang S, Li JF, Wang YW (2012) Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions. J Clean Prod 32:81–87.  https://doi.org/10.1016/j.jclepro.2012.03.014 CrossRefGoogle Scholar
  7. 7.
    Sreejith P, Ngoi BK (2000) Dry machining: machining of the future. J Mater Process Technol 101:287–291.  https://doi.org/10.1016/S0924-0136(00)00445-3 CrossRefGoogle Scholar
  8. 8.
    Lawal SA, Choudhury IA, Nukman Y (2013) A critical assessment of lubrication techniques in machining processes: a case for minimum quantity lubrication using vegetable oil-based lubricant. J Clean Prod 41:210–221.  https://doi.org/10.1016/j.jclepro.2012.10.016 CrossRefGoogle Scholar
  9. 9.
    Tamada IS, Montagnolli RN, Lopes PRM, Bidoia ED (2012) Toxicological evaluation of vegetable oils and biodiesel in soil during the biodegradation process. Brazilian J Microbiol 43:1576–1581.  https://doi.org/10.1590/S1517-83822012000400042 CrossRefGoogle Scholar
  10. 10.
    Chinchanikar S, Choudhury SK (2015) Machining of hardened steel—experimental investigations, performance modeling and cooling techniques: a review. Int J Mach Tools Manuf 89:95–109.  https://doi.org/10.1016/j.ijmachtools.2014.11.002 CrossRefGoogle Scholar
  11. 11.
    Minh DT, The LT, Bao NT (2017) Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools. doi:  https://doi.org/10.1177/1687814017710618
  12. 12.
    An Q, Wang C, Xu J et al (2014) Experimental investigation on hard milling of high strength steel using PVD-AlTiN coated cemented carbide tool. Int J Refract Met Hard Mater 43:94–101.  https://doi.org/10.1016/j.ijrmhm.2013.11.007 CrossRefGoogle Scholar
  13. 13.
    Maruda RW, Krolczyk GM, Feldshtein E et al (2017) Tool wear characterizations in finish turning of AISI 1045 carbon steel for MQCL conditions. Wear 372:54–67.  https://doi.org/10.1016/j.wear.2016.12.006 CrossRefGoogle Scholar
  14. 14.
    Wojciechowski S, Maruda RW, Nieslony P, Krolczyk GM (2016) Investigation on the edge forces in ball end milling of inclined surfaces. Int J Mech Sci 119:360–369.  https://doi.org/10.1016/j.ijmecsci.2016.10.034 CrossRefGoogle Scholar
  15. 15.
    Wojciechowski S, Twardowski P, Pelic M (2014) Cutting forces and vibrations during ball end milling of inclined surfaces. In: Procedia CIRP. pp 113–118Google Scholar
  16. 16.
    Çaydaş U, Kuncan O, Çelik M (2017) AISI 52100 rulman çeliğinin işlenebilirliğinin yüzey pürüzlülüğü, takım ömrü ve sıcaklık kriterlerine göre araştırılmasıGoogle Scholar
  17. 17.
    Kissler H (2000) KSS-bedingte Kosten in derspanenden Metallbearbeitung als Anreiz für die Trockenbearbeitung. In: 12 th Int. Colloq. Tribol. pp 901–913Google Scholar
  18. 18.
    Kaynak Y (2014) Evaluation of machining performance in cryogenic machining of Inconel 718 and comparison with dry and MQL machining. Int J Adv Manuf Technol 72:919–933.  https://doi.org/10.1007/s00170-014-5683-0 CrossRefGoogle Scholar
  19. 19.
    Qian L, Hossan MR (2007) Effect on cutting force in turning hardened tool steels with cubic boron nitride inserts. J Mater Process Technol 191:274–278.  https://doi.org/10.1016/j.jmatprotec.2007.03.022 CrossRefGoogle Scholar
  20. 20.
    Wakabayashi T, Sato H, Inasaki I (1998) Turning using extremely small amounts of cutting fluids. JSME Int J Ser C 41:143–148.  https://doi.org/10.1299/jsmec.41.143 CrossRefGoogle Scholar
  21. 21.
    Quiza R, Figueira L, Davim JP (2008) Comparing statistical models and artificial neural networks on predicting the tool wear in hard machining D2 AISI steel. Int J Adv Manuf Technol 37:641–648.  https://doi.org/10.1007/s00170-007-0999-7 CrossRefGoogle Scholar
  22. 22.
    Chinchanikar S, Choudhury SK (2014) Hard turning using HiPIMS-coated carbide tools: wear behavior under dry and minimum quantity lubrication (MQL). Meas J Int Meas Confed 55:536–548.  https://doi.org/10.1016/j.measurement.2014.06.002 CrossRefGoogle Scholar
  23. 23.
    Le TS, Tran MD, Nguyen DB, Nguyen VC (2013) An investigation on effect of characteristics of the peanut oil MQL on tool life in hard turning 9CrSi steel. Int J Mach Mach Mater 13:428.  https://doi.org/10.1504/IJMMM.2013.054275 Google Scholar
  24. 24.
    Liao YS, Lin HM, Chen YC (2007) Feasibility study of the minimum quantity lubrication in high-speed end milling of NAK80 hardened steel by coated carbide tool. Int J Mach Tools Manuf 47:1667–1676.  https://doi.org/10.1016/j.ijmachtools.2007.01.005 CrossRefGoogle Scholar
  25. 25.
    Ginting YR, Boswell B, Biswas W, Islam N (2015) Advancing environmentally conscious machining. Procedia CIRP 26:391–396CrossRefGoogle Scholar
  26. 26.
    Sohrabpoor H, Khanghah SP, Teimouri R (2015) Investigation of lubricant condition and machining parameters while turning of AISI 4340. Int J Adv Manuf Technol 76:2099–2116CrossRefGoogle Scholar
  27. 27.
    Maruda RW, Krolczyk GM, Nieslony P et al (2016) The influence of the cooling conditions on the cutting tool wear and the chip formation mechanism. J Manuf Process 24:107–115.  https://doi.org/10.1016/j.jmapro.2016.08.006 CrossRefGoogle Scholar
  28. 28.
    Barczak LM, Batako ADL, Morgan MN (2010) A study of plane surface grinding under minimum quantity lubrication (MQL) conditions. Int J Mach Tools Manuf 50:977–985CrossRefGoogle Scholar
  29. 29.
    Bhowmick S (2011) Minimum quantity lubrication machining of aluminum and magnesium alloysGoogle Scholar
  30. 30.
    Morgan MN, Barczak L, Batako A (2012) Temperatures in fine grinding with minimum quantity lubrication (MQL). Int J Adv Manuf Technol 60:951–958CrossRefGoogle Scholar
  31. 31.
    Tai BL, Stephenson DA, Furness RJ, Shih AJ (2014) Minimum quantity lubrication (MQL) in automotive powertrain machining. Procedia CIRP 14:523–528CrossRefGoogle Scholar
  32. 32.
    Obikawa T, Kamata Y, Asano Y et al (2008) Micro-liter lubrication machining of Inconel 718. Int J Mach Tools Manuf 48:1605–1612.  https://doi.org/10.1016/j.ijmachtools.2008.07.011 CrossRefGoogle Scholar
  33. 33.
    Rahman M, Kumar AS (2001) Evaluation of minimal of lubricant in end milling. Int J Adv Manuf Technol 18:235–241CrossRefGoogle Scholar
  34. 34.
    Mao C, Huang Y, Zhou X et al (2014) The tribological properties of nanofluid used in minimum quantity lubrication grinding. Int J Adv Manuf Technol 71:1221–1228.  https://doi.org/10.1007/s00170-013-5576-7 CrossRefGoogle Scholar
  35. 35.
    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 Behav Sci 195:2742–2747CrossRefGoogle Scholar
  36. 36.
    Sharma VS, Dogra M, Suri NM (2009) Cooling techniques for improved productivity in turning. Int J Mach Tools Manuf 49:435–453CrossRefGoogle Scholar
  37. 37.
    Dixit US, Sarma DK, Davim JP (2012) Machining with minimal cutting fluid. In: Environ. Friendly Mach. Springer, pp 9–17Google Scholar
  38. 38.
    Debnath S, Reddy MM, Yi QS (2014) Environmental friendly cutting fluids and cooling techniques in machining: a review. J Clean Prod 83:33–47CrossRefGoogle Scholar
  39. 39.
    Mahadi MA, Choudhury IA, Azuddin M, Nukman Y (2017) Use of boric acid powder aided vegetable oil lubricant in turning AISI 431 steel. In: Procedia Eng. pp 128–136Google Scholar
  40. 40.
    Esfe MH, Karimipour A, Yan W-M et al (2015) Experimental study on thermal conductivity of ethylene glycol based nanofluids containing Al 2 O 3 nanoparticles. Int J Heat Mass Transf 88:728–734CrossRefGoogle Scholar
  41. 41.
    Fedele L, Colla L, Bobbo S (2012) Viscosity and thermal conductivity measurements of water-based nanofluids containing titanium oxide nanoparticles. Int J Refrig 35:1359–1366CrossRefGoogle Scholar
  42. 42.
    Li X, Zou C, Lei X, Li W (2015) Stability and enhanced thermal conductivity of ethylene glycol-based SiC nanofluids. Int J Heat Mass Transf 89:613–619CrossRefGoogle Scholar
  43. 43.
    Karimi A, Sadatlu MAA, Saberi B et al (2015) Experimental investigation on thermal conductivity of water based nickel ferrite nanofluids. Adv Powder Technol 26:1529–1536CrossRefGoogle Scholar
  44. 44.
    Peng DX, Kang Y, Hwang RM et al (2009) Tribological properties of diamond and SiO 2 nanoparticles added in paraffin. Tribol Int 42:911–917CrossRefGoogle Scholar
  45. 45.
    Sharma AK, Tiwari AK, Dixit AR (2015) Mechanism of nanoparticles functioning and effects in machining processes: a review. Mater Today Proc 2:3539–3544CrossRefGoogle Scholar
  46. 46.
    Vamsi Krishna P, Srikant RR, Nageswara Rao D (2011) Solid lubricants in machining. Proc Inst Mech Eng Part J J Eng Tribol 225:213–227.  https://doi.org/10.1177/1350650111398172 CrossRefGoogle Scholar
  47. 47.
    Kiliçay K, Ulutan M (2016) Investigation of the solid lubrication effect of commercial boron-based compounds in end milling. Int J Precis Eng Manuf 17:517–524.  https://doi.org/10.1007/s12541-016-0065-1 CrossRefGoogle Scholar
  48. 48.
    Deshmukh P, Lovell M, Sawyer WG, Mobley A (2006) On the friction and wear performance of boric acid lubricant combinations in extended duration operations. Wear 260:1295–1304.  https://doi.org/10.1016/j.wear.2005.08.012 CrossRefGoogle Scholar
  49. 49.
    Caliskan H, Kurbanoglu C, Kramar D, et al (2012) Hard Milling Operation Of AISI O2 Cold Work Tool Steel By Carbide Tools 15:21–26Google Scholar
  50. 50.
    Turkish Standards Institute (1998) Turkish Standard TS ISO 7005–2Google Scholar
  51. 51.
    Kursuncu B, Caliskan H, Guven SY Wear behavior of cryogenically treated TiN coated carbide cutting tool while face milling Inconel 718 Superalloy. 1–7Google Scholar
  52. 52.
    Vamsi Krishna P, Srikant RR, Nageswara Rao D (2010) Experimental investigation on the performance of nanoboric acid suspensions in SAE-40 and coconut oil during turning of AISI 1040 steel. Int J Mach Tools Manuf 50:911–916.  https://doi.org/10.1016/j.ijmachtools.2010.06.001 CrossRefGoogle Scholar
  53. 53.
    Tebaldo V, di Confiengo GG, Faga MG (2017) Sustainability in machining: “Eco-friendly” turning of Inconel 718. Surface characterisation and economic analysis. J Clean Prod 140:1567–1577.  https://doi.org/10.1016/j.jclepro.2016.09.216 CrossRefGoogle Scholar
  54. 54.
    Kursuncu B, Çalışkan H (2016) The effect of multilayer nanocomposite TIAlSIN/ TISIN /TIALN coating on cutting forces in face milling of Inconel 718 Superalloy. Istanbul, pp 11–14Google Scholar
  55. 55.
    Davis B, Schueller JK, Huang Y (2015) Study of ionic liquid as effective additive for minimum quantity lubrication during titanium machining. Manuf Lett.  https://doi.org/10.1016/j.mfglet.2015.04.001

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2017

Authors and Affiliations

  1. 1.Faculty of Engineering, Mechanical Engineering DepartmentBartin UniversityBartinTurkey
  2. 2.Faculty of Engineering, Metallurgy and Material Engineering DepartmentBartın UniversityBartinTurkey

Personalised recommendations