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Evaluation of the effects of machining parameters on MQL based surface grinding process using response surface methodology

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Abstract

Grinding is a precision machining process widely used for close tolerance and good surface finish. Due to aggregate of geometrically undefined cutting edges and material removal in the form of microchips, grinding requires more specific energy as friction is greater in the grinding interface. The optimum use and proper penetration of coolant is the prime requirement which is achieved by effective cooling and lubrication. In this research, a greater focus is on MQL technique, which is economical and eco-friendly. The paper presents important aspects of the grinding process considering the surface roughness and cutting force. The experiments were carried out on horizontal surface grinding machine using Response surface methodology (RSM). In addition, evaluation of grinding performance parameters like coefficient of friction, cutting forces, temperature and specific grinding energy for different machining environments has been discussed. The lowest surface roughness and coefficient of friction observed was 0.1236 μm and 0.3906, respectively for MQL grinding, whereas lowest specific grinding energy was found as 18.95 N/mm2 in wet grinding. The temperature recorded in MQL grinding was 29.07 °C, which is marginally higher than wet condition. The response obtained as cutting forces, temperature and surface roughness under MQL mode encourages its use for machining AISI D3 type material compared to other grinding environments. Mathematical modeling showing the relation between the factors and response variables was established using Response surface methodology. Regression analysis was performed to determine the accuracy of mathematical model, significant factors and interaction effects of parameters on responses.

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Authors and Affiliations

  1. Department of Mechanical Engineering, K.V.N. Naik Institute of Engineering Education & Research, Nashik, 422005, India

    Rahul R. Chakule

  2. Department of Mechanical Engineering, Yashwantrao Chavan College of Engineering, Nagpur, 441110, India

    Sharad S. Chaudhari

  3. Department of Mechanical Engineering, Late G. N. Sapkal College of Engineering, Nashik, 422005, India

    P. S. Talmale

Authors
  1. Rahul R. Chakule
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  2. Sharad S. Chaudhari
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  3. P. S. Talmale
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Correspondence to Rahul R. Chakule.

Additional information

Recommended by Associate Editor Young Whan Park

Rahul R. Chakule is currently a Ph.D. scholar in Mechanical Engineering at Rastrasant Tukdoji Maharaj Nagpur University. He received his master degree in Mechanical Engineering in 2006 from Sant Gadgebaba Amravati University, India. He is working as Assistant Professor in Mechanical Engineering at Savitribai Phule Pune University. His research interests are in manufacturing engineering, optimization techniques and application of nanofluid for machining process.

Sharad S. Chaudhari received his Ph.D. in Mechanical Engineering from Rastrasant Tukdoji Maharaj Nagpur University in 2011. He is currently a Professor of Mechanical Engineering at RTM Nagpur University, India. His research interests are in minimum quantity lubrication, agricultural and engineering research, study of industrial hazard, study of foundry issues and modernization.

P. S. Talmale obtained her master degree in Mechanical Engineering in 2012 from Sant Gadgebaba Amravati University, India. She is currently an Assistant Professor in Mechanical Engineering at Savitribai Phule Pune University. Her research interests are in computer aided design and manufacturing, product design and development, manufacturing science.

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Chakule, R.R., Chaudhari, S.S. & Talmale, P.S. Evaluation of the effects of machining parameters on MQL based surface grinding process using response surface methodology. J Mech Sci Technol 31, 3907–3916 (2017). https://doi.org/10.1007/s12206-017-0736-6

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  • DOI: https://doi.org/10.1007/s12206-017-0736-6

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