Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

The requirement of cost-effective and ecological production systems is crucial in the competitive market. In this regard, the focus is shifted towards sustainable and cleaner machining processes. Besides the clean technologies, effective parametric control is required for machining materials (such a...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology Vol. 117; no. 5-6; pp. 1915 - 1934
Main Authors: Javid, Hassan, Jahanzaib, Mirza, Jawad, Muhammad, Ali, Muhammad Asad, Farooq, Muhammad Umar, Pruncu, Catalin I., Hussain, Salman
Format: Journal Article
Language:English
Published: London Springer London 01.11.2021
Springer Nature B.V
Subjects:
Advanced manufacturing technologies
CAE) and Design
Chemical properties
Computer-Aided Engineering (CAD
Cutting speed
Ecological effects
Elevation
Energy consumption
Engineering
Feed rate
High strength low alloy steels
Industrial and Production Engineering
Lubricants & lubrication
Lubrication
Machinability
Manufacturing
Material removal rate (machining)
Mechanical Engineering
Media Management
Morphology
Nanofluids
Optimization
Original Article
Parametric analysis
Parametric statistics
Process parameters
Process variables
Productivity
Silicon dioxide
Steel
Surface roughness
Sustainability
System effectiveness
Tool life
Tool wear
Tooling
Turning (machining)
Minimum quantity lubrication
Surface roughness
Sustainability
Nanofluids
HSLA steel
Tool life
ISSN:0268-3768, 1433-3015
Online Access:Get full text
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Summary:The requirement of cost-effective and ecological production systems is crucial in the competitive market. In this regard, the focus is shifted towards sustainable and cleaner machining processes. Besides the clean technologies, effective parametric control is required for machining materials (such as High Strength Low Alloy Steels) specifically designed for high strength applications having superior physio-chemical properties. Therefore, the machinability complexities require optimized solutions to reduce temperature elevation and tooling costs and improve machining of these materials. Complying to the market needs, this research examines the effectiveness of nanofluid on tool life, wear mechanisms, surface roughness (Ra), surface morphology, and material removal rate (MRR) in turning of 30CrMnSiA (HSLA) using minimum quantity lubrication (MQL) and SiO 2 -H 2 O nanofluids (NF-MQL). A systematic investigation based on physical phenomena involved is carried out considering four process parameters (cutting speed (V C ), feed rate (F r ), depth of cut (D OC ), and mode of lubrication for machining. F r is found as the vital parameter for surface roughness while MRR is highly influenced by D OC regardless of lubrication approach. One-step sustainability technique is applied, in which process variables used for roughing conditions are analogous to attain surface comparable to finished machining without compromising process efficiency and demonstrate its feasibility through optimal settings under NF-MQL. Multi-response optimization proved the NF-MQL machining condition as the best alternative which result in 28.34% and 5.09% improvements for surface roughness and MRR, respectively. Moreover, the use of SiO 2 is recommended over MQL due to lower energy consumption, low tool wear, and better surface integrity, sustainable liquid, and related costs.
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ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-021-07776-y