Experimental analysis of cutting force during machining difficult to cut materials under dry, mineral oil, and TiO2 nano-lubricant

Abstract

Difficult-to-machine materials, e.g., Titanium alloys, are highly applicable in diverse industries that yield strength and wear resistance. However, they prove difficult to machine due to high vibration, leading to high cutting forces during the machining process. This vibration occurs from chip discontinuity and thereby leads to high friction between the cutting tool and workpiece. In order to minimize these challenges, lubricants are employed in machining operations to reduce frictional and other unnecessary cutting forces and improve surface finish. This research focuses on studying the nano-lubricant effects in reducing cutting forces in the machining of TI-6AL-4V-ELI alloy. Also, carry out a comparative study of dry, mineral oil, and TiO2 nano-lubricant during face-milling machining for optimal performance. Additionally, the study develops a predictive mathematical model for cutting force using a Taguchi L9 orthogonal array. A two-step approach was employed to develop the nano-lubricant before the machining process. The dynamometer is used to collect the cutting force data at the end of each sample. The Results show that the lubrication conditions play a significant role in the reduction of cutting forces. The mineral oil-based-TiO2 nano-lubricant reduces the cutting force by 19 % compared with the mineral oil during the machining of TI-6AL-4V-ELI alloy. Furthermore, the optimal parameters to reduce cutting forces during face milling of TI-6AL-4V-ELI alloy are cutting speed at 3000 rpm, 200 mm/min feed rate, 0.3 mm depth of cut to obtain the minimum cutting force 30 (N). This study concludes that the application of TiO2 nanoparticles in mineral oil significantly improves the thermal and mechanical properties, which leads to a reduction of cutting force.

Application of Cement-Based Carbon Fiber Material in Construction of Building Durability

“…However, due to the frequent agglomeration of carbon fiber materials, it is difficult to disperse in cement-based composite materials, studies have shown that adding dispersants or using ultrasonic technology can make them have better dispersibility in solution. Various studies have shown that doping carbon fiber materials into cement-based composites can effectively reduce or improve the electrical conductivity of their surfaces, in order to adapt to various environmental needs, and enhance its tensile strength and flexural strength [ 4 , 5 ].…”

Machine Learning-Based Modelling and Predictive Maintenance of Turning Operation under Cooling/Lubrication for Manufacturing Systems

“…When we run the lathe machine, we need to control the cutting speed and depth of the cut feed rate; the operator owns these parameters [14]. As per the basic knowledge, we consider three levels of cutting speed and cut depth and four feed rate levels.…”

A review on effects of process parameters in milling challenging materials under nanofluid-based MQL conditions

“…R a increases as “ f ” and “ a p ” increase because of the high friction that forms at the tool-chip interface, as well as the increasing chip area, temperature and “ F r ”. According to Muthusamy et al (2015), “ T L ” rose as “ V c ”, “ f ” and “ a p ” were reduced. As a result, the end milling process can benefit from the use of low “ V c ”, low “ f ” value and low “ a p ”. Okokpujie and Tartibu (2021) demonstrated the impact of “ V c ” on “ F r ” under three different lubrication conditions. For each of the three cutting circumstances, the lowest “ F r ” was attained at the fastest “ V c ”.…”

“…The earlier researchers discussed their work on a variety of challenging materials for various milling operations, including nickel-based, titanium-based, manganese-based superalloys and medium and hardened alloy steels (Soori and Mohammed, 2021; Okokpujie and Tartibu, 2021).…”