Multi-Objective Optimization for Grinding of AISI D2 Steel with Al2O3 Wheel under MQL

Abstract

In the present study, the machinability indices of surface grinding of AISI D2 steel under dry, flood cooling, and minimum quantity lubrication (MQL) conditions are compared. The comparison was confined within three responses, namely, the surface quality, surface temperature, and normal force. For deeper insight, the surface topography of MQL-assisted ground surface was analyzed too. Furthermore, the statistical analysis of variance (ANOVA) was employed to extract the major influencing factors on the above-mentioned responses. Apart from this, the multi-objective optimization by Grey–Taguchi method was performed to suggest the best parameter settings for system-wide optimal performance. The central composite experimental design plan was adopted to orient the inputs wherein the inclusion of MQL flow rate as an input adds addition novelty to this study. The mathematical models were formulated using Response Surface Methodology (RSM). It was found that the developed models are statistically significant, with optimum conditions of depth of cut of 15 µm, table speed of 3 m/min, cutting speed 25 m/min, and MQL flow rate 250 mL/h. It was also found that MQL outperformed the dry as well as wet condition in surface grinding due to its effective penetration ability and improved heat dissipation property.

Repairing Hybrid Mg–Al–Mg Components Using Sustainable Cooling Systems

“…Therefore, when magnesium-containing hybrid components are going to be mechanized, it is necessary to take certain security measures regarding the lubricants or coolant systems employed. Depending on the material or materials with which magnesium is combined, different lubrication/cooling techniques can be used [17,18] both individually (dry machining [19][20][21][22][23][24][25][26][27][28][29][30][31], minimum quantity lubrication (MQL) [30][31][32][33][34][35][36][37][38][39][40][41][42], solid lubrication [43][44][45][46][47], cryogenic cooling [48][49][50][51][52][53][54][55], gaseous cooling [56][57][58][59][60][61], nanofluids …”

The Influence of the Depth of Cut in Single-Pass Grinding on the Microstructure and Properties of the C45 Steel Surface Layer

“…However, the introduction of this technology for the manufacture of components is faced with a number of difficulties. Grinding energy efficiency depends on the appropriate selection of cutting conditions, grinding wheel, workpiece material, and lubrication conditions [15,16]. There are difficulties with obtaining a repeatable result as it is difficult to achieve the assumed depth of hardening and to obtain the assumed hardness after grinding, which results in the necessity of applying the so-called softening grinding.…”

Multi-Objective Optimization of Energy Consumption and Surface Quality in Nanofluid SQCL Assisted Face Milling

“…Similarly, R: GRC range, Q: mean Grey relational coefficient of each cutting parameter at three different levels (Appendix B). Weights for each response were computed using Equation (8). Finally, Equation (9) was used to calculate grey relation grades and is given in Table 4.…”

“…Owing to this fact, the use of cooling-lubricating agents in machining is widespread to date. However, the growing concerns for the environment and human health-related problems have forced manufacturers to look for an alternative as well as better cooling-lubrication modes [6][7][8].Considering those aspects, for decades, the alternative mode of cooling-lubrication in machining has been the use of small droplets of agents under high air pressure so that the impinged sprays penetrate in between the interfaces. These droplets serve two functions: (i) they reduce friction by creating a thin film in between the material bodies [9], and (ii) they enhance heat dissipation by absorbing and removing heat from that zone [10].…”

“…Owing to this fact, the use of cooling-lubricating agents in machining is widespread to date. However, the growing concerns for the environment and human health-related problems have forced manufacturers to look for an alternative as well as better cooling-lubrication modes [6][7][8].…”