Performance evaluation of Ti–6Al–4V machining using nano-cutting fluids under minimum quantity lubrication
- 91 Downloads
Abstract
Owing to their superior mechanical, physical, and chemical characteristics, titanium and its alloys are broadly used in different industrial applications such as military, aerospace, power generation, and automotive. However, titanium alloys are inherently difficult to cut materials due to the high generated temperature during machining. In addition to flood cooling, several other techniques were employed to reduce the harmful effect and the generated temperature and generally improve titanium alloys machinability. In this paper, an attempt is made to utilize nano-additives to improve the cooling efficiency of minimum quantity lubrication (MQL) during machining titanium alloys. The main objective of the current research is to investigate the influence of dispersed multi-walled carbon nanotubes (MWCNTs) into vegetable oil by implementing the MQL technique during turning of Ti–6Al–4V. The novelty here lies on enhancing the MQL heat capacity using different concentrations of nano-fluid in order to improve Ti–6Al–4V machinability. Different cutting tests were performed and relevant data were collected. The studied design variables were cutting speed, feed rate, and percentage of added nano-additives (wt%). It was found that 2 wt% MWCNT nano-fluid reduced the power consumption by 11.5% in comparison with tests performed without any nano-additives, while the same concentration reduced the flank wear by 45%.
Keywords
Ti–6Al–4V alloy Nano-fluid Multi-walled carbon nanotubes (MWCNTs) Tool wear MachinabilityPreview
Unable to display preview. Download preview PDF.
References
- 1.Choragudi A, Kuttolamadom MA, Jones JJ, Mears ML, Kurfess T (2010) Investigation of the machining of titanium components in lightweight vehicles. in SAE International Congress. https://doi.org/10.4271/2010-01-0022
- 2.Schauerte O (2003) Titanium in automotive production. Adv Eng Mater 5(6):411–418. https://doi.org/10.1002/adem.200310094 CrossRefGoogle Scholar
- 3.Ezugwu E, Wang Z (1997) Titanium alloys and their machinability—a review. J Mater Process Technol 68(3):262–274. https://doi.org/10.1016/S0924-0136(96)00030-1 CrossRefGoogle Scholar
- 4.Shokrani A, Dhokia V, Newman ST (2012) Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids. Int J Mach Tools Manuf 57:83–101. https://doi.org/10.1016/j.ijmachtools.2012.02.002 CrossRefGoogle Scholar
- 5.Davim JP (ed) (2011) Machining of hard materials. Springer Science & Business Media. https://doi.org/10.1007/978-1-84996-450-0
- 6.Kishawy H, Li L, El-Wahab A (2006) Prediction of chip flow direction during machining with self-propelled rotary tools. Int J Mach Tools Manuf 46(12):1680–1688. https://doi.org/10.1016/j.ijmachtools.2005.06.006 CrossRefGoogle Scholar
- 7.Ghadimi A, Saidur R, Metselaar H (2011) A review of nanofluid stability properties and characterization in stationary conditions. Int J Heat Mass Transf 54(17):4051–4068. https://doi.org/10.1016/j.ijheatmasstransfer.2011.04.014 CrossRefGoogle Scholar
- 8.Daungthongsuk W, Wongwises S (2007) A critical review of convective heat transfer of nanofluids. Renew Sust Energ Rev 11(5):797–817. https://doi.org/10.1016/j.rser.2005.06.005 CrossRefGoogle Scholar
- 9.Choi S et al (2001) Anomalous thermal conductivity enhancement in nanotube suspensions. Appl Phys Lett 79(14):2252–2254. https://doi.org/10.1063/1.1408272 CrossRefGoogle Scholar
- 10.Lee C-G, Hwang YJ, Choi YM, Lee JK, Choi C, Oh JM (2009) A study on the tribological characteristics of graphite nano lubricants. Int J Precis Eng Manuf 10(1):85–90. https://doi.org/10.1007/s12541-009-0013-4 CrossRefGoogle Scholar
- 11.He Y, Jin Y, Chen H, Ding Y, Cang D, Lu H (2007) Heat transfer and flow behaviour of aqueous suspensions of TiO2 nanoparticles (nanofluids) flowing upward through a vertical pipe. Int J Heat Mass Transf 50(11):2272–2281. https://doi.org/10.1016/j.ijheatmasstransfer.2006.10.024 CrossRefMATHGoogle Scholar
- 12.Zhang Y, Li C, Jia D, Zhang D, Zhang X (2015) Experimental evaluation of MoS2 nanoparticles in jet MQL grinding with different types of vegetable oil as base oil. J Clean Prod 87:930–940. https://doi.org/10.1016/j.jclepro.2014.10.027 CrossRefGoogle Scholar
- 13.Prabhu S, Uma M, Vinayagam B (2015) Surface roughness prediction using Taguchi-fuzzy logic-neural network analysis for CNT nanofluids based grinding process. Neural Comput & Applic 26(1):41–55. https://doi.org/10.1007/s00521-014-1696-8 CrossRefGoogle Scholar
- 14.Raju RA, Andhare A, Sahu NK (2017) Performance of multi-walled carbon nanotube-based nanofluid in turning operation. Mater Manuf Process 32(13):1–7CrossRefGoogle Scholar
- 15.Singh RK, Sharma AK, Dixit AR, Tiwari AK, Pramanik A, Mandal A (2017) Performance evaluation of alumina-graphene hybrid nano-cutting fluid in hard turning. J Clean Prod 162:830–845. https://doi.org/10.1016/j.jclepro.2017.06.104 CrossRefGoogle Scholar
- 16.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
- 17.Wang Y, Li C, Zhang Y, Li B, Yang M, Zhang X, Guo S, Liu G (2016) Experimental evaluation of the lubrication properties of the wheel/workpiece interface in MQL grinding with different nanofluids. Tribol Int 99:198–210. https://doi.org/10.1016/j.triboint.2016.03.023 CrossRefGoogle Scholar
- 18.Sharma P, Sidhu BS, Sharma J (2015) Investigation of effects of nanofluids on turning of AISI D2 steel using minimum quantity lubrication. J Clean Prod 108:72–79. https://doi.org/10.1016/j.jclepro.2015.07.122 CrossRefGoogle Scholar
- 19.Huang W-T et al (2014) Robust design of using MWCNTs in minimum quantity lubrication. Appl Mech Mater 670-671:11–21CrossRefGoogle Scholar
- 20.Roy, S. and A. Ghosh (2013) High speed turning of AISI 4140 steel using nanofluid through twin jet SQL system. In Proceedings of ASME 2013 international manufacturing science and engineering conference, Madison, pp MSEC2013–1067. https://doi.org/10.1115/MSEC2013-1067
- 21.Setti D, Sinha MK, Ghosh S, Venkateswara Rao P (2015) Performance evaluation of Ti–6Al–4V grinding using chip formation and coefficient of friction under the influence of nanofluids. Int J Mach Tools Manuf 88:237–248. https://doi.org/10.1016/j.ijmachtools.2014.10.005 CrossRefGoogle Scholar
- 22.Deiab I, Raza SW, Pervaiz S (2014) Analysis of lubrication strategies for sustainable machining during turning of titanium Ti-6Al-4V alloy. Procedia CIRP 17:766–771. https://doi.org/10.1016/j.procir.2014.01.112 CrossRefGoogle Scholar
- 23.Cheap-tubes/products/multi-walled-carbon-nano-tubes (MWCNTs). https://www.cheaptubes.com/product-category/multi-walled-carbon-nanotubes (access date: December 13th 2017)
- 24.Chang H, Wu YC, Chen XQ, Kao MJ (2000) Fabrication of cu based nanofluid with superior dispersion. National Taipei University of Technology, TaipeiGoogle Scholar
- 25.Hwang Y, Lee JK, Lee CH, Jung YM, Cheong SI, Lee CG, Ku BC, Jang SP (2007) Stability and thermal conductivity characteristics of nanofluids. Thermochim Acta 455(1):70–74. https://doi.org/10.1016/j.tca.2006.11.036 CrossRefGoogle Scholar
- 26.Huang J, Wang X, Long Q, Wen X, Zhou Y, Li L (2009) Influence of pH on the stability characteristics of nanofluids. In Photonics and optoelectronics. SOPO 2009. Symposium on. 2009. IEEEGoogle Scholar
- 27.Loos, M. (2014) Carbon nanotube reinforced composites: CNT Polymer Science and Technology: Elsevier. https://doi.org/10.1016/B978-1-4557-3195-4.00001-1
- 28.Vandsburger, L. (2010) Synthesis and covalent surface modification of carbon nanotubes for preparation of stabilized nanofluid suspensions. https://digitool.Library.McGill.CA:80/R/-?func=dbin-jumpfull&object_id=40744&silo_library=GEN01
- 29.Ezugwu E et al (2005) Evaluation of the performance of CBN tools when turning Ti–6Al–4V alloy with high pressure coolant supplies. Int J Mach Tools Manuf 45(9):1009–1014. https://doi.org/10.1016/j.ijmachtools.2004.11.027 CrossRefGoogle Scholar
- 30.Krishna PV, Srikant R, Rao DN (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(10):911–916. https://doi.org/10.1016/j.ijmachtools.2010.06.001 CrossRefGoogle Scholar
- 31.Prasad M, Srikant R (2013) Performance evaluation of nano graphite inclusions in cutting fluids with MQL technique in turning of AISI 1040 steel. Int J Res Eng Technol 2(11):381–393CrossRefGoogle Scholar
- 32.Li B, Li C, Zhang Y, Wang Y, Jia D, Yang M, Zhang N, Wu Q, Han Z, Sun K (2017) Heat transfer performance of MQL grinding with different nanofluids for Ni-based alloys using vegetable oil. J Clean Prod 154:1–11. https://doi.org/10.1016/j.jclepro.2017.03.213 CrossRefGoogle Scholar
- 33.Su Y, Gong L, Li B, Liu Z, Chen D (2016) Performance evaluation of nanofluid MQL with vegetable-based oil and ester oil as base fluids in turning. Int J Adv Manuf Technol 83(9–12):2083–2089. https://doi.org/10.1007/s00170-015-7730-x CrossRefGoogle Scholar
- 34.Selvaraj DP, Chandramohan P, Mohanraj M (2014) Optimization of surface roughness, cutting force and tool wear of nitrogen alloyed duplex stainless steel in a dry turning process using Taguchi method. Measurement 49:205–215. https://doi.org/10.1016/j.measurement.2013.11.037 CrossRefGoogle Scholar
- 35.Patole P, Kulkarni V (2017) Experimental investigation and optimization of cutting parameters with multi response characteristics in MQL turning of AISI 4340 using nano fluid. Cogent Eng 4(1):1303956CrossRefGoogle Scholar
- 36.Sharma AK, Tiwari AK, Dixit AR (2015) Progress of nanofluid application in machining: a review. Mater Manuf Process 30(7):813–828. https://doi.org/10.1080/10426914.2014.973583 CrossRefGoogle Scholar
- 37.Khandekar S, Sankar MR, Agnihotri V, Ramkumar J (2012) Nano-cutting fluid for enhancement of metal cutting performance. Mater Manuf Process 27(9):963–967. https://doi.org/10.1080/10426914.2011.610078 CrossRefGoogle Scholar
- 38.Jawaid A, Che-Haron C, Abdullah A (1999) Tool wear characteristics in turning of titanium alloy Ti-6246. J Mater Process Technol 92:329–334CrossRefGoogle Scholar
- 39.Sarhan AA, Matsubara A (2011) Compensation method of the machine tool spindle thermal displacement for accurate monitoring of cutting forces. Mater Manuf Process 26(12):1511–1521. https://doi.org/10.1080/10426914.2010.544825 CrossRefGoogle Scholar
- 40.Alabi A, Ajiboye T, Olusegun H (2010) Investigating the cutting forces in heat treated medium carbon steel when turning on a lathe machine. J Eng Des Technol 8(1):80–93. https://doi.org/10.1108/17260531011034664 Google Scholar
- 41.Sayuti M et al (2013) Cutting force reduction and surface quality improvement in machining of aerospace duralumin AL-2017-T4 using carbon onion nanolubrication system. Int J Adv Manuf Technol 65:1–8CrossRefGoogle Scholar
- 42.Lee K, Hwang Y, Cheong S, Choi Y, Kwon L, Lee J, Kim SH (2009) Understanding the role of nanoparticles in nano-oil lubrication. Tribol Lett 35(2):127–131. https://doi.org/10.1007/s11249-009-9441-7 CrossRefGoogle Scholar
- 43.Rapoport L, Nepomnyashchy O, Lapsker I, Verdyan A, Moshkovich A, Feldman Y, Tenne R (2005) Behavior of fullerene-like WS2 nanoparticles under severe contact conditions. Wear 259(1):703–707. https://doi.org/10.1016/j.wear.2005.01.009 CrossRefGoogle Scholar
- 44.Bagaber SA, Yusoff AR (2017) Multi-objective optimization of cutting parameters to minimize power consumption in dry turning of stainless steel 316. J Clean Prod 157:30–46. https://doi.org/10.1016/j.jclepro.2017.03.231 CrossRefGoogle Scholar