REVIEW ON MINIMUM QUANTITY LUBRICATION

Transcription

1 Volume 119 No , ISSN: (on-line version) url: REVIEW ON MINIMUM QUANTITY LUBRICATION A.V.Sandeep Reddy, S. Ajay Kumar, Geena Prasad Department of mechanical engineering Amrita Vishwa Vidyapeetham, Amritapuri campus India Abstract Minimum Quantity Lubrication (MQL) is one of the best solution to minimise the wastage of liquid and for the effective usage of the lubricant that is employed. The development of minimum quantity lubrication system can reduce the health problems and environmental degradation caused by the cutting fluids. This technique can be used as an alternative to the machining done with dry and wet type lubrication systems. The MQL technique involves a less quantity of lubricant that is distributed to the tool work interface with the usage of compressed air flow. In this paper an in depth study has been made for the examination of minimum quantity lubrication. Various criteria like selection of cutting fluid, different types of MQL techniques and selection of satisfactory lubricants for various machining operations have been determined with respect to cutting tool materials. Index Terms MQL; Machining; Cutting fluid; Lubricant I. INTRODUCTION Machining is defined as a material removal process in which a part of material will be removed from the work piece using convenient cutting tools. Machining of alloys at high speeds is required to minimize the machining time and increase the Production rate. The Machining of Aerospace Alloys like the Titanium and Nickel based alloys which have high strength and hardness but have low heat conductivities, huge amount of heat is generated because of the strength of the work piece and the loads acting on the tool at high speeds. The heat generated during the machining of these alloys will affect the work piece quality (surface finish and dimensional accuracy).due to the heat generated between the work piece and the tool many other properties like tool life of tool,time taken for machining,surface roughness, tool wear,chip thickness,chip formation,power consumption,chip breaking behaviour also get effected, so many cooling and lubricating cutting fluids have been developed to reduce the heat that has been generated during the machining operation. But the conventional cutting fluids are causing many problems like the pollution of environment, hazards to operators during the working with them, wastage of fluid, contamination of soil during their disposal. As the concern for the environment and sustainability is increasing and the in order to reduce the above effects caused by some biodegradable fluids, researchers have found some solutions to these problems by using different techniques like dry machining,wet machining,cryogenic cooling,minimum quantity lubrication,solid lubrication. The main advantages of using cutting fluids are: It improves the tool life, it prevents the metal from corrosion, it reduces the chip formation and surface finish is improved. Flooded coolant system is the most widely used type of coolant for various machining operations, but due to its application of ejecting flooded liquid at a single point it is often uneconomical and not environment friendly II. CRITERIA FOR SELECTION OF CUTTING FLUID The selection of the cutting fluid is done on the following criteria: Type of cutting material used. Type of work piece used. Type of machining process employed. 1451

2 III.MINIMUM QUANTITY LUBRICATION As we know that flooded coolant system is not a preferred system for various machining process because of its unfavourable properties like wastage, not environmental friendly, uneconomical[1]. So there is a need for using a method for optimization of the above different properties. Minimum quantity lubrication provides the best alternative in the optimization process. In the process of MQL a very little amount of the cutting fluid is used to reduce the heat generated and friction developed.[1] This type of process is mostly suited for process like drilling, milling turning, etc. The lubricant used is in small quantity which is atomised in air and flows towards the cutting zone with a high flow rate. The lubricant is sprayed on the cutting zone with the help of nozzles to provide high pressure. There is a reduction of usage of liquid when compared to conventional systems. The coolant can be supplied in two different ways - External feed systems and Internal feed systems. A. External Feed System It consists of a reservoir or coolant tank which is connected to the spray nozzles. The assembly can be done near or on the machine and has independent air adjusting and coolant flow for a balanced coolant delivery. The nozzle can be easily fitted to the spindle head. This system is useful for single process like drilling, Turning, etc. [1] B. Internal Feed System The supply of lubricant takes place the Spindle of the machine, the tool holding system, and directly on the cutting tool edge.it is divided into two types - one channel system and two channel system. In one channel system, the mixing of aerosol takes place outside the spindle whereas in case of two channel system the lubricant is mixed directly inside the spindle [1]. IV.ADVANTAGES OF MINIMUM QUANTITY LUBRICATION.[1] The advantages of the minimum quality lubrication can be primarily classified into two types: Financial advantages and Ecological advantages The financial advantages includes the recycling of dry metal chips, reduction on the money spent for control and care of coolant, decrease in different costs associated with coolant like purchase cost, ware housing costs, transportation costs,tool life will be comparatively more, supply and disposal of the coolant can be omitted. Whereas the ecological advantages includes : skin diseases and airway diseases can be avoided, used emulsions will not accumulate, accidents due to leakage of coolant can be avoided, risk of accidents at work can be reduced as it is near dry machining. V. STUDIES ON MINIMUM QUANTITY LUBRICATION. Khan et.al, 2006, provides an experimental investigation on MQL by vegetable oils in turning of AISI-1060 steel. The results shows that MQL provided an increased tool life, high dimensional accuracy, high tool life, low cutting temperatures and an improved chip tool interaction [3]. Khan et.al, 2009, gives what are the effects of MQL by vegetable based oil when compared to dry and wet machining in different characteristics. The results found that the chips are smoother and brighter, low built up edges are formed, high tool life, high productivity, improved velocity and an improved surface finish with the help of MQL when compared to both dry and wet machining [4]. The effects of six different strategies on different properties in the turning of titanium alloy was studied by Ibrahim et.al, Dry vegetable oil MQL, MQCL vegetable oil, cooled air, flood, cryogenic are the six different strategies analysed.mql was found to be the best alternative in terms of surface finish, tool wear, energy consumed [5]. Prasad et.al, 2013, demonstrates the usage of Nano fluids in minimum quantity lubrication for turning operation. MQL assisted machining provided better performance compared to dry machining. MQL provided better 1452

3 performance in terms of surface roughness, tool wear, temperatures and different other properties like biodegradability and microbial contamination have been reduced [6]. Hasan et.al, 2014, tells about the effects of MQL with vegetable oil as cutting fluid when compared to dry and wet machining. The results show that the chip tool interface temperature, tool wear, surface finish have been giving better properties with the use of MQL when compared to dry and wet machining [7]. Ali et.al, 2011, shows an experimental procedure with MQL by cutting oil on different characteristics. The results show that tool wear rate, dimensional inaccuracy and surface roughness have been significantly reduced with the use of MQL when compared to dry and wet machining [8]. Imran et.al, focuses on the surface roughness produced during the turning of Incoloy 800 with the use of Taguchi method. The results show that the usage of MQL has reduced the surface roughness [9]. Turning operation was conducted on the magnesium alloy using the tungsten carbide cutting tool with dry and minimum quantity lubrication by Viswanathan et.al, Minimum quantity lubrication conditions are best for optimization of performance for cutting forces, cutting temperature, tool wear and surface roughness. The MQL technique provides the best results when comparing with dry machining [10]. Maheswara Reddy et.al, 2016, analysed the surface roughness of Inconel 718 for turning operation with the help of minimum quantity lubrication. The surface roughness of machined work material during (Ws2) solid lubricant assisted with minimum quantity lubrication and the results shows that about 35 % were increased when compared to Minimum quantity lubrication machining alone. The (Ws2) solid lubricant can work effectively as additive to oil based cutting fluid [11]. Experiment was conducted on comparing the both dry and fluid grinding process based on the temperature distribution and the surface integrity of the work piece by Mohammadajafar et.al, The investigations on MQL technique has shown best results and good lubrication in the grinding process. The results show that there is better heat transfer and the temperature at the contact point remains the same [12]. Grinding operation was conducted with different lubrication and different cooling conditions for ABNT 4340 steel by Silva et.al, The tangential cutting force were reduced by using minimum quantity lubrication (MQL) with convectional cooling condition [13]. Amit et.al,2014 analysed the turning operation on AISI alloy steel by using minimum quantity lubrication for different machining parameters such as cutting force, surface roughness and tool wear.the cutting performance of the MQL technique is better than of dry and conventional machining. After using the MQL technique there is gradual increase in tool life, surface finish and the cutting fluid wastage can be reduced to a larger extent [14]. Nourredine Boubekri et.al,2015,gives us a review on minimum quantity lubrication, the benefits health affects involved in minimum quantity lubrication and its future research[15]. VI. CONCLUSION These literatures clearly show the advantages of MQL when compared to dry and wet machining and shows that the conventional flooded system can be replaced by MQL system. Many different properties like tool wear, surface roughness, chip formation, tool life, productivity, dimensional accuracy, low cutting temperatures can be enhanced with the help of MQL technique. Other properties like biodegradability and non-microbial contamination have also been achieved with the use of MQL. REFERENCES 1.Madhukar, Shravan Aitha, Vidyanand Pakka and Sreeram Reddy G, A Critical review on Minimum Quantity Lubrication (MQL) Coolant System for Machining Operations, September Nourredine Boubekri, Vasim Shaikh, Minimum Quantity Lubrication (MQL) in Machining: Benefits and Drawbacks, journal of Industrial and Intelligent Information Vol. 3, No. 3, September

4 3.KHAN M.M.A., DHAR N.R, Performance evaluation of minimum quantity lubrication by vegetable oil in terms of cutting force, cutting zone temperature, tool wear, job dimension and surface finish in turning AISI steel, August Khan M.M.A., Mithu M.A.H., Dhar N.R., Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using vegetable oil-based cutting fluid,may Ibrahim Deiaba, Syed Waqar Razaa, Salman Pervaiz,Analysis of Lubrication Strategies for Sustainable Machining during Turning of Titanium Ti-6Al-4V alloy, Prasad.M.M.S, Srikant R.R,performance evaluation of nano graphite inclusions in cutting fluids with mql technique in turning of aisi 1040 steel, Hasan M F, Dwivedi A, Study and Analysis of Natural Oil Based Cutting Fluids Using Minimum Quantity Lubrication System for Alloy Steel, IJPRET, Volume 3 (2): 50-68, Ali S.M, Dhar N.R, Dey S.K., effect of minimum quantity lubrication (mql) on cutting performance in turning medium carbon steel by uncoated carbide insert at different speed-feed combinations, Md Imran Ansari A and Kotiveerachary B,Study of the Effect of Minimum Quantity Lubrication on the Surface Roughness of Incoloy 800 during Turning Operation,Feb Viswanathan R, Ramesh S, Subburam V, Measurement and optimization of performance characteristics in turning of Mg alloy under dry and MQL conditions, 12 February Uma Maheshwera Reddy Paturia, Yesu Ratnam Maddua, Ramalinga Reddy Maruria, Suresh Kumar Reddy Narala, Measurement and analysis of surface roughness in WS2 solid lubricant assisted minimum quantity lubrication (MQL) turning of Inconel 718, Mohammadjafar Hadada, Alireza Sharbatib, Thermal Aspects of Environmentally Friendly-MQL grinding Process, Silva L. R., Bianchi E. C., Catai R. E., Fuse R. Y., Franca T. V. and Aguiar P. R., Study on the Behaviour of the Minimum Quantity Lubricant MQL Technique under Different Lubricating and Cooling Conditions When Grinding ABNT 4340 Steel May, Amit Vishwakarma, Sachin Jain, Pushpendra Kumar Sharma, Analysis of effect of Minimum Quantity Lubrication on different machining parameters Cutting Force, Surface Roughness and Tool Wear by Hard Turning of AISI-4340 Alloy Steel a Review, December Nourredine Boubekri, Vasim Shaikh, Minimum Quantity Lubrication (MQL) in Machining: Benefits and Drawbacks, journal of Industrial and Intelligent Information Vol. 3, No. 3, September

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