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

Abstract

Considering the significance of improving the energy efficiency, surface quality and material removal quantity of machining processes, the present study is conducted in the form of an experimental investigation and a multi-objective optimization. The experiments were conducted by face milling AISI 1045 steel on a Computer Numerical Controlled (CNC) milling machine using a carbide cutting tool. The Cu-nano-fluid, dispersed in distilled water, was impinged in small quantity cooling lubrication (SQCL) spray applied to the cutting zone. The data of surface roughness and active cutting energy were measured while the material removal rate was calculated. A multi-objective optimization was performed by the integration of the Taguchi method, Grey Relational Analysis (GRA), and the Non-Dominated Sorting Genetic Algorithm (NSGA-II). The optimum results calculated were a cutting speed of 1200 rev/min, a feed rate of 320 mm/min, a depth of cut of 0.5 mm, and a width of cut of 15 mm. It was also endowed with a 20.7% reduction in energy consumption. Furthermore, the use of SQCL promoted sustainable manufacturing. The novelty of the work is in reducing energy consumption under nano fluid assisted machining while paying adequate attention to material removal quantity and the product’s surface quality.

Modeling and performance evaluation of Al2O3, MoS2 and graphite nanoparticle-assisted MQL in turning titanium alloy: an intelligent approach

“…The used three NFs have a different molecular structure, and reportedly the smaller-sized NFs are more desired as they have the capability for an effective penetration inside the interfaces [34]. Furthermore, an increase in NF concentration causes an increase in the viscosity, yet viscosity that in the system can be altered because of higher local temperature [35].For instance, the nano-fluid when used in suspension with the base oil causes acceleration of heat transfer that facilitates the flush of materials [36,37]. These phenomena might be the possible cause of the change of the surface.…”

Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9

“…In objective weight methods, the weights of criteria (responses) are measured based on the available data without intervention of an expert’s opinion [ 24 ]. The well-known techniques are entropy [ 25 ], standard deviation [ 26 ], criteria importance through inter-criteria correlation (CRITIC) [ 27 ], and the maximizing deviation method [ 28 ]. In contrary, the subjective methods involve the expert’s opinion [ 24 ].…”

Eco-Friendly Cutting Fluids in Minimum Quantity Lubrication Assisted Machining: A Review on the Perception of Sustainable Manufacturing

“…The philosophy of MQL advocated that the minimum utilization of cutting fluid is very much advantageous in terms of the economy because it significantly minimizes the lubrication cost [7]. MQL, also famous as "Near-dry machining" [8], Small quantity lubrication [9,10] and "Micro lubrication," [11] is the most useful practice of conveying cutting fluid to the interface of tool and workpiece. Nevertheless, in MQL system, a jet of cutting fluid is utilized that makes it expensive; additionally, there are some difficulties concerned with the reaching ability of the lubricant in the machining zone.…”