Investigation on hard turning temperature under a novel pulsating MQL environment: An experimental and modelling approach

Abstract

Generation of total heat in hard turning largely influenced the cutting tool wear, tool life and finishing quality of work-surface. Thus, the measurement of this heat in terms of temperature becomes a necessity for achieving favourable machining performances. Therefore, this work presents a novel study on temperature measurement in three different zones during hard turning operation of 4340 grade steel under pulsating MQL environment. Temperatures are measured at three different locations namely chip-tool interface, flank face, and machined work surface (near to tool-work contact) and the location wise temperature is termed as chip tool interface temperature (T), flank face temperature (Tf) and machined work surface temperature (Tw) correspondingly. The temperature T and Tf are measured with help of K-type thermocouple while Tw is measured by Fluke make infra-red thermal camera. Pulsating MQL significantly reduced the temperature as the maximum temperature is noticed 110 °C which corresponds to chip-tool interface temperature (T) at highest speed (200 m/min) condition. In each test, the order of temperature follow the trend as: T > Tf > Tw. Considering average of all 16 temperatures, T is 14.42% greater than Tf and 39.36% larger than Tw while Tf is 21.79% greater than Tw. Experimental results concludes that the cutting speed is the most influencing factor followed by depth of cut for both T and Tf, whereas depth of cut is the most influencing factor for Tw. Further, these temperatures are predicted using linear regression, and absolute mean error (MAE) for responses T, Tf, and Tw is noticed as 1.848%, 0.542%, and 3.766% individually. Additionally, the optimum setting of input terms are estimated using WPCA (weighted principal component analysis) and found to be dc1 (0.1 mm) − fr2 (0.08 mm/rev) − vc2 (100 m/min) − Pt2 (2 s).

A Comparative Performance Investigation of Single- and Double-Nozzle Pulse Mode Minimum Quantity Lubrication Systems in Turning Super-Duplex Steel Using a Weighted Pugh Matrix Sustainable Approach

“…The levels of feed and depth of cut were also considered based on the literature and the manufacturer's recommendations for steel materials. Pulse time (1 s, 3 s, and 5 s) was taken based on the author's previous research article [36]. Each input variable has three different levels, and all of the experimental details of the machining conditions are listed in Table 2.…”

What micro-mechanical testing can reveal about machining processes

“…Subsurface damage that occurs during machining is different for various materials. For example, the subsurface damage in steel/advanced alloys could be manifester usually a white layers and plastic deformations [87]; the subsurface damages from the cutting of high entropy alloys and ceramics are grain refinement [88,89]; the subsurface damages from the cutting of hard-brittle crystal (Si and Ga 2 O 3 ) are amorphous phase layers and dislocations [61,90]; and the subsurface damages from the cutting of soft-brittle crystal (CaF 2 , ZnSe, and HgCdTe) are dislocations only [36,[91][92][93]. How the mechanical properties of these damaged layers have changed in comparison to the material before machining and how they affect the subsequent machining processes can be determined by analyzing the nanoindentation load-displacement curves of the material surfaces before and after machining.…”