Dissertations/Theses - Department of Industrial and Production Engineering
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Item Performance evaluation of different types of cutting fluids in Minimum Quantity of Lubrication (MQL) machining of alloy steel by coated carbide insert(Department of Industrial and Production Engineering, BUET, 2009-11) Sonia Sultana; Dhar, Dr. Nikhil RanjanHigh Clltting tempenlture is inherent during machining which shortens the tQollife and deteriorates the job ql.llliity. This problcm becomes morc acute when the jobs are difficn1t to machine and are to be used undcr dynamic loading. Cutting flnid application is the most common strutegy to improve the tool life and the product quality. But COllventionalcutting fluids are not that effective in high production machining particularly ill continuous culting of materials like ~teels. More over cutting fluids are the major sOl.lree of environments pollution, soil contamination and inhalation problems. Minimum quantity lubrication (MQL) with vegetable oil or clitting oil is cnvironment friendly machining technique. MQL refers to the use of cutting fluid~ of only u minutc amount-typically of a flow rate of 50 to 500 mLihwhich is about three to four orders of magnitude lowcr thalllhe amount commonly used in flood cooling condition. Effects of MQL on cutting performance of 42CrMo4 steel in respect of chip-too! interface temperature, chip formation, cutting forces, tool wear and prodllct quality have been studied using coatcd carbidc insert (SNMM-TN 2000). Three types of cutting fluids namely soluble oil, vegetable oil and VG 68 cutting oil have been used to compare the relative perfonnance of those culling fluid, with each other as well as with that of dry condition. Compared to dry condition, MQL perfonned better mainly due to sub<;tantial reduction in cutting temperature that enabling favorable chip-tool interaction. This also facilitated the substantial reduction in tool wear, dimensional inaccuracy and surface roughness. The results indicated that the use of minimum quantity lubrication (MQL) by VG 68 cutting oil performed better in comparison to other entting fluids.Item Tool wear and surface roughness prediction in turning steel under minimum quantity lubrication(Department of Industrial and Production Engineering, BUET, 2009-10) Mithun Ali, Syed; Dhar, Dr. Nikhil RanjanMinimum quantity lubrication (MQL) refers to the use ofcuuing fluid, of only a minute amount typically of a flow rate of 50 to 500 ml/hour which is about three to four. orders or magnitude l()\'er than the e to experimental values. The rc>ults of the ANN model show that thc model can be used for the optimization of the cutling process Le. culling parameters can be set in advance prior to pcrform machining operations for cfficient and economic production and for the purpose of manufacturing process planning in a properly designed MQL environment.Item Effects of minimum quantity of lubrication (MQL) on tool wear and surface roughness in turning AISI-1040 steel with uncoated carbide tool(Department of Industrial and Production Engineering, BUET, 2005-09) Abu Hayat Mithu, Md.; Dhar, Dr. Nikhil RanjanMinimum quantity lubrication (MOL) refers to the use of culling fluids of only a minute amount-typically of a flow rate of 50 to 500 mllhour which is aboul three to four orders of magnitude lower than the amount commonly used in flood cooling condition. The concept of minimum quanlily lubrication, sometimes referred to as near dl)' lubrication or micro lubrication, has been suggested since a decade ago as a means of addressing the issues of 'environmental intrusiveness and occupational hazards associated with theairborne cutting fluid panicles on faclory shop floors. The minimization of cutting fluid also leads to economical benefits by way of saving lubricant costs and workpiece/iool/machine cleaning cycle lime. During machining, the cutting tool generally undergoes both flank wear and crater wear. Flank wear generally causes an increase in the cutting forces, dimensional inaccuracy and vibration. Crater wear takes place on the rake face of the tool where the chip slides over the tool surface. This was aimed to study the role of culling fluid, tool and workpiece material, 1001geometry and cutting conditions on machinability. Proper selection and application of cutting fluid generally improves tool life. But surface finish did not improve significantly. Wearing of cutting tools not only causes ioss of the cutting edges or tips of the inserts but loss of the entire insert after wear of all Ihe corners. From an environmental perspective, therefore, the significant waste is not the portion of the tool worn away by the tool-work contact, but the remaining portion of the tooi that is disposed after its useful iile. Compared to the dry and wet machining, MOL machining performed many superiors mainly due to reduction in cutting zone temperature enabling favorable chip formation and chip-tool interaction. it also provides reduction in tool wear, which enhanced the tool life, dimensionai accuracy and product quality. Furthermore, it provides environment friendiiness and improves the machinability characteristics.Item Effects of minimum quantity lubrication by vegetable oil-based cutting fluid on machinability of steel(Department of Industrial and Production Engineering, BUET, 2005-12) Muhshin Aziz Khan, Mohammad; Dhar, Dr. Nikhil RanjanMinimum quantity lubrication refers to the use of cutting fluids of only a minute amount-typically of a flow rate of 50 to 500 ml/hour-:-which is about three to four orders of magnitude lower than the amount commonly used in flood cooling condition, where, for example, up to 10 liters of fluid can be dispensed per minute. The concept of minimum quantity lubrication, sometimes referred to as near dry lubrication or micro lubrication, has been suggested since a decade ago as a means of addressing the issues of environmental intrusiveness and occupational hazards associated with the airborne culling fluid particles on factory shop floors. The minimization of cutting fluid also leads to economical benefits by way of saving lubricant costs and workpiece/tool/machine cleaning cycle time. Significant progress has been made in dry and semidry machining recently, and minimum quantity lubrication (Mal) machining in particular has been accepted as a successful semidry application because of its environmentally friendly characteristics. A number of studies have shown that Mal machining can show satisfactory performance in practical machining operations. However, there has been little investigation of the cutting fluids to be used in Mal machining. In this regard the proposed research work has been carried out with a view to study the effects of minimum quantity lubrication (Mal) by vegetable oil-based cutting fluid on the cutting performance of AISI x 9310 steel, as compared to completely dry and wet machining in terms of chiptool interface temperature and tool wear reduction, tool life increment and machined surface protection. An approach based on the process parameters (speeds, feeds and depth of cut) has also been performed to identify the suitable MQl nozzle position for better cooling action. In the study, the minimum quantity lubrication will be provided with a spray of air and vegetable oil. Compared to the dry or wet machining, MQl machining performed much superior mainly due to substantial reduction in cutting zone temperature enabling favorable chip formation and chip-tool interaction. It also provides substantial reduction in tool wear, which enhanced the tool life, and surface finish. Furthermore, it provides environment friendliness (maintaining neat, clean and dry working area, avoiding inconvenience and health hazards due to heat, smoke, fumes, gases etc. and preventing pollution of the surroundings) and improves the machinability characteristics.