Investigation on surface roughness, tool wear and cutting power in MQL turning of bio-medical Ti-6Al-4V ELI alloy with sustainability

Abstract

Ti-6Al-4V ELI (Grade 23) is highly recommended for bio-materials and due to its low thermal conductivity and chemically reactive properties, machinability is poor. Thus the current work emphasized on the selection of appropriate cooling technique and optimal cutting parameters for machining of Ti-6Al-4V ELI alloy with sustainability analysis for surface roughness, flank wear and cutting power. Initially, the cutting performances under dry, flood and MQL environments are compared and MQL is observed to better performed. At lower speed (70 m/min), MQL exhibited 26.38% and 19.69% lesser surface roughness relative to dry and flood cooling individually. At the same cutting condition, MQL assisted cutting resulted in lower flank wear relative to dry (157. 33%) and flood cooling (40%). Further, a detailed investigation has been made under MQL through Taguchi L18 design of experiments. The major mechanisms for flank wear are found to be abrasion, chipping and notch wear. Optimal data set through Grey relational analysis is found to be v1 (70 m/min), f1 (0.1 mm/rev) and d1 (0.1 mm) and improved. Quadratic regression model is found to be significant for prediction of responses. Sustainability Pugh matrix assessment revealed that MQL environment enhanced the economical, technological as well as environmental and operator health aspects. Reduction of energy consumption by 53.96% and savings of carbon footprints by 68.46 kg of CO2 observed under MQL at optimal conditions and thus saves manufacturing cost.

Machinability characteristics analysis of hard turning operation on AISI 4340 steel using physical vapor deposition multilayer coated carbide cutting tool in the dry environment

“…53 According to ISO, the allowable amount of surface roughness is less than 1.6 μm. 54 Because the depth of cut remained less than the tool's nose radius and the flank wear standards were set at less than 0.2 mm. The flank wear occurred at the nose corner.…”

Evaluation and Performance Improvement of Environmentally Friendly Sustainable Turning of 6063 Aluminum Alloy in Dry Conditions Using Grey Relational Analysis

“…The efficiency of the established mathematical model is justified through adjusted R-squared, R-squared, and predicted R-squared and good precision values [33]. The confidence level fixed to investigate the predicted model is a 95% level of significance [34]. Regarding actual parameters, the equation [35] for GRG based on response surface methodology is given as Eq.…”

Parametric optimization to establish eco-friendly nanofluid minimum quantity lubrication (NMQL) practice for turning superalloy Inconel 718

“…Shukla et al (2023) noticed reductions in machined surface roughness and cutting force by 9.6% and 7.15%, respectively, under MQL machining of steel grade 304 as compared to dry turning. Rajan et al (2022) experienced significant 40% and 157.33% lesser tool wear under the MQL regime, respectively, as compared to flood and dry situations during the turning of Ti-6Al-4V ELI alloy. Özbek et al (2022) also observed that the eco-friendly MQL technique results in notable machining performance in terms of surface roughness, tool wear, cutting tool vibration amplitude and cutting temperature when compared with a dry environment during the turning of a high-strength Vanadis 10 tool steel alloy.…”