constantly rolling over component surface [100 Cr6 steel (62 HRC)] under high pressures. Hassan et al. [9] optimized the ball burnishing parameters, mainly the burnishing force and number of passes using response surface methodology. El-Axir [4] developed a mathematical model for roller Abstract The roller burnishing tool is used in computer numerical control lathe to superfinish the turning process. The tool and workpiece materials considered are tungsten carbide (69 HRC) and EN-9 Grade Alloy Steel (10 HRC), respectively. The input parameters are burnishing force, feed, roller contact width and number of passes. The response surface methodology is used to develop a mathematical model and optimize the parameters for the surface characteristics (such as surface roughness and surface hardness). The optimum surface roughness and its surface hardness are 0.2 µm and 18 HRC, respectively. The surface roughness is reduced by 94.5% and hardness is improved by 41.7%. The contributing variable of each parameter is estimated using analysis of variance method. The morphology of the burnished surface is investigated using scanning electron microscope.

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This article provides an improved lubrication system for minimum quantity lubrication machining wherein oil is locally supplied and individually controlled at different heating zones during machining operation. The proposed lubrication method, that is, a multi-point minimum quantity lubrication system, is aimed at improving energy efficiency and environmental friendliness of cutting process. An experimental system is devised in which process parameters, such as air pressure, stroke volume (i.e. amount of oil in one stroke of pump), stroke frequency, and oil distribution factor (i.e. proportion of oil at rake and flank face), are individually controlled for each supply system. The devised system is demonstrated through machining of Ti-6Al-4V. The results of the experimental study on effects of oil quantity and supply method on specific cutting energy, tool wear, and machined surface quality are presented and discussed and corroborated with scientific evidence. The study suggests that distributing oil at the rake face and the flank face in unequal proportions can be more beneficial than injecting it solely at a single location. The investigation also provides mechanism of multi-point minimum quantity lubrication machining through analysis of adiabatic shear zones, observed in scanning electron microscope images of chips.

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The article presents minimum quantity lubrication (MQL) machining of Ti-6Al-4V in a collective framework of multiple objectives-quality (surface roughness), environmental friendliness (specific cutting energy, tool wear, and oil consumption), and production (material removal rate and tool wear). In one of the first of its kind, the proposed approach uses cutting fluid parameters (oil quantity in the oil+air mixture, air pressure, and proportion of oil at the rake and flank face) along with machining parameters in multi-objective meta-heuristic optimization. The investigation reveals that the three objectives are distinct functions of process inputs. Thus, focus on one of the objectives-quality, production, and environmental aspects-hampers the others. A reasonable balance between the three aspects can be achieved through simultaneous optimization. Precise control over cutting fluid parameters, especially the oil proportion at rake and flank face, is a major factor that helps in improving environmental