Experimental Investigation of Nano Cutting Fluids as a Sustainable Cooling Technique in Turning Operation

Transcription

1 Volume-6, Issue-4, July-August 2016 International Journal of Engineering and Management Research Page Number: Experimental Investigation of Nano Cutting Fluids as a Sustainable Cooling Technique in Turning Operation Raghvendra Singh 1, Dr. M. K. Pal 2 1 PG Scholar, Department of Mechanical Engineering, B.I.T. Durg, (C.G.), INDIA 2 Senior Associate Professor, Department of Mechanical Engineering, B.I.T Durg, (C.G.) INDIA ABSTRACT Metal cutting operations generate the heat and forces due to the friction and energy lost in deforming the work piece. There are the several types of cutting fluids. The disadvantages of mineral based straight oils and soluble oils are poor heat dissipating properties and increase fire risk. On other hand the synthetic fluids no contain petroleum or mineral oil and based on alkaline organic and inorganic compounds. It reduce heat and very less environmental and health hazards. The objective of this work is to analysis the experimental results upon using the different types of Nano metal powder such as molybdenum disulphide (MoS 2 ), graphite, Nano boric acids (NBA) in synthetic based cutting fluids as glycerin and compared to dry machining with respect to cutting temperature and surface qualities. According to the solid heat transfer enhancement theory the thermal conductivity of liquids and heat transfer capacity increased by adding the solid Nano particles in it. Compared study on the effect of NBA on Nano graphite fluid and Nano MoS 2 fluids with glycerin base fluid, the temperature and surface roughness were analyzed and shown the result that average temperature is reduce by Nano MoS 2 with NBA. This is lower than Nano graphite addition with NBA by 15.26% to 17% and from dry condition 24% to 40%. With compared study, result show that the molybdenum disulphide MoS 2 nanoparticles based glycerin with Nano boric acid gives more efficient for cutting process as compared to dry machining and other used cutting fluids. Keywords--- Synthetic fluid, nanoparticle, graphite, MoS2, NBA, sustainable machining I. INTRODUCTION Cutting fluids play the important role in manufacturing in the form of coolant and lubrication special for metalworking process such as machining. There are various types of cutting fluids. Usually the oils and oilwater are mostly used in industrial machining which creates the environment pollutions, health hazards, rusting and corrosion the metal. For reducing this problem stainable manufacturing and machining process are introduced [1]. In recent trends is to use of new concepts in the development of sustainable products and materials, processes and systems in developing improved sustainability scoring methods for products and processes [2] which increase social, economic and environment impact on manufacturing process. A. F. Clarencs, K. F. Hayes, S. J. Skeelos, (2006) presents a new method for cooling, lubrication and evacuate chips in metalworking operations using supercritical carbon dioxide (scco2). They shows that soybean oil dissolved in scco2 performs significantly better than straight soybean oil [3]. Minimum quantity lubrication (MQL) also advance technique used for machining process which reduced cutting temperature by 5%-10% compared to dry machining [4], N. R. Dhar, M. T. Ahmed, S. Islam, (2007) and tool-wear can be predicted within 10% when the effect of near dry machining process than dry machining [5]. Some researchers used the synthetic ester as the base cutting fluid and resultthat, biodegradable synthetic esters are found to be optimal cutting fluids for MQL machining than minerals oils and vegetable oils [6-7]. E. A. Rahim, H. Sasahara, (2011) shows the synthetic ester based cutting fluids reduced the cutting temperature 10%- 25% and cutting forces 5%-25% as high speed drilling of titanium alloy[8]. Hagiwara M, Chen S, Jawahir IS, (2008), using orthogonal cutting condition in AISI 1045 work material and shows the synthetic ester based cutting fluid reduced cutting temperature 10-30% and cutting force 5-28% for MQL condition compared to dry condition [9]. The present work deals with the experimental investigation of Nano cutting fluidssustainable cooling technique in turning operation,with the uses of different type of Nano metal powder in glycerin based cutting fluid. 414 Copyright Vandana Publications. All Rights Reserved.

2 II. METHODOLOGY There are thee approaches to enhancement the thermal conductivity by Brownian motion of nanoparticles, liquid layering of base fluid surrounding the nanoparticles and nanoparticles aggregation. This mechanism responsible for the thermal conductivity enhancementof liquid fluids: (a) Brownian Motion: Nanoparticles moves with the help of base fluid. Due to Brownian motion of base fluid nanoparticles collides with each other. Hence the solid-solid heat transfer mode presence and increase the overall thermal conductivity of Nanofluid. The Brownian motion is a diffusive process with diffusive constant D which given by the Stokes Einstein formula: Where: DD = KT 3Πηdd K is the Boltzman constant T is the temperature N is viscosity of the fluid d is the nanoparticle diameter η is viscosity of fluid (b) Liquid Layering: In compared to pure liquid, the fluid containing solid have more ordered flow. In Nano fluids the interaction between liquid-solid generate a strong bonding and creates crystal like structure in the liquid surrounding the nanoparticles. These structural changes in liquid fluids have significant effects on various properties such as solidliquid phase transfer, heat exchange, flow rate, viscosity of fluids etc. Such changes responsible for lattice vibration due to which highly heat transfer enhancement occurs. (c) Nanoparticle Aggregation: Another region for heat transfer enhancement is the clustering of nanoparticles. When nanoparticles dispersed into liquid fluid the accumulating nanoparticles creates paths of lower thermal resistance which responsible for changes overall thermal conductivity.the low volume concentration of nanoparticles given the particle-free space for fast movement the nanoparticles. (d) Solid Heat Transfer Enhancement Theory: According to the heat transfer theory, the heat transfer capacity of solid particle higher than liquid and gases. Thus the nanoparticles dispersed in base fluids because it can increase the thermal conductivity of liquids and convective heat transfer capacity of Nano fluid. Nano particles act as anti-wear, friction reducing agent and high load carrying capacity. At low concentration the specific energy is decreases but when increase the concentration of particles the specific energy is increases from 2% to 3% or less than 5% weight fraction mixed in liquid fluid for better result requirement. Due to small size it fill-up the pick and valley of work piece and made a smooth surfaces and cutting process is easy done. III. EXPERIMENTAL DESIGN AND CUTTING PARAMETERS Turning operation performed on the lathe machine. Infra-red thermometer measuring range 0 C- 550 C used to measure the cutting temperature closed to cutting zone. 1.5L oil tank capacity of lubrication pump with pressure meter used for cooling and lubrication of work piece. Mild steel work piece material having length 350 mm and diameter 20mm were used for three successive turning operations. HSS single point cutting tool are used in turning operation. There are three types of additives molybdenum disulfide (MoS 2 ), Nano boric acid (NBA) and Nano graphite powder (NGP) are used for nanoparticles in glycerin based liquid fluids 3.1 Preparation of Nano Fluids: When dispersed metal particle in fluid it does not equal disperse in liquid for overcome this problem by using the surfactant such as Sodium Dodecyl Benzene Sulphonate (SDBS). The main function of surfactant is to provide stability of Nanoparticles in liquid fluid. Electrolytic metal powders are some stable in liquid there are less required to use of surfactant in it. 415 Copyright Vandana Publications. All Rights Reserved.

3 (a) Nano Boric Acid, Glycerin liquid, Nano (b) Prepared NBA fluid, NGP fluid and Graphite powders, Nano MoS 2 powder. Nano MoS2 with glycerin. Figure-1: Nanoparticles additives and prepared cutting fluids 3.2 Experimental Condition and Cutting parameters: All the component and equipment pre-set in the operation zone. The cooling devise set near the lathe machine and heighted to the cutting point for better flow rate. Infra-red thermometer or thermocouple was used for cutting temperature measurement. One end of thermocouple touch into the work piece near to the tool- work contact and other end connected to the infra-red thermometer or using the infra-red emission target to cutting tool point. Cutting parameter such as speed, feed rate, depth of cut etc. shown in table-1 as experimental condition and cutting parameter. Experimental condition Cutting speed (rpm) Feed rate Depth of cut Pressure Liquid fluid and lubricant TABLE-1 Experiment condition and cutting parameter Parameter setting 350rpm, 550rpm, 850rpm 1.1 mm/sec 1.5mm 0.2Mpa 0.5Mpa Water, glycerin, 3.3 Experimental Approaches: Experiment-1 Two type of machining condition was employed in turning operation namely dry condition and near MQL condition. In this section dry cooling, water based cooling and glycerin based cutting fluid cooling were performed. First of turning operation perform without any coolant namely dry condition with preset cutting parameter at three times of cutting speed 350rpm, 550rpm and 850rpm and depth of cut 1.5 mm at constant feed rate. These parameters are same in all cutting section. Under the each cutting speed, cutting temperature was measure and summarized in Table-2. After dry condition next operation performed for further 100 mm length of work piece, using the fresh water as cutting fluid under the similar cutting parameters. Cutting temperature measured by infra-red thermometer, four times to measure the temperature as per job cutting process. After measuring all the temperature, the average temperature is calculated for each job production. TABLE: 2. Measured cutting temperature at different machining conditions from experiment-1 Spindle Speed in (rpm) Cutting Fluid Temperature (after 10sec) in C average temperature ( C) 350 rpm Dry condition Fresh Water Glycerin Copyright Vandana Publications. All Rights Reserved.

4 550 rpm Dry condition Fresh water Glycerin rpm Dry condition Fresh water Glycerin Experiment-2: By the primarily analysis, it is shown that the glycerin based cutting fluid gives minimum cutting temperature as compare to dry turning and water based cutting fluids. So the next experiment approaches to which type of Nano fluids (combination of glycerin and nanoparticles) gives the better result in cooling and lubrication process on turning operation. Hence the each type of Nano particles mixed to liquid fluid (glycerin) separately to form a Nano cutting fluids and perform same cutting operation as experiment-1.measured cutting temperature and average temperature for each job summarized in table-3. TABLE: 3Measured cutting temperature at different machining conditions from experiment-2 Spindle speed in rpm Cutting Fluid Temperature(after0sec) in C Average Temperature C Nano boric acid rpm (NBA) fluid NGP fluid rpm Nano MoS 2 fluid Nano boric Acid (NBA) fluid NGP fluid Nano MoS 2 fluid rpm Nano boric acid (NBA) fluid NGP fluid Nano MoS 2 fluid. Experiment-3: In this section we can perform the experiment to study the effect of NBA on work piece when adding the Nano cutting fluids of graphite and MoS 2 separately. In this section there are two types of nanoparticles cutting fluids prepared first graphite Nano fluid and second MoS 2 Nano fluid with adding NBA. Concentration of nanoparticle to glycerin liquid same as 4% weight fraction of 1L glycerin liquid. TABLE: 4.Measured cutting temperature at different machining conditions from experiment-3 Spindle speed in rpm Cutting fluid Temperature (after 10sec) in C Average temperature C 350 rpm Nano graphite with NBA Nano MoS 2 with NBA Copyright Vandana Publications. All Rights Reserved.

5 550 rpm Nano graphite with NBA Nano MoS 2 with NBA IV. RESULT AND DISCUSSION 4.1 Analysis of Results from Experiment 1: Remarkable differences under the different cooling and lubrication conditions were observed. According to table-2, dry cutting condition produced the maximum cutting temperature and roughness, which is mainly due to absence of coolants and lubricants. Cutting Temperature, T ( C) Temperature differances among Dry air, Water and Glycerin based Cooling Air Water Glycerin Cutting Speed, S (rpm) Figure-2: Shows Temperature differences among Dry, Water and Glycerin based cooling From the graphical representation of average cutting temperature of various cutting fluids, it is clear that the average cutting temperature under glycerin based lower than those of dry cutting condition and water based cutting fluid. Average cutting temperature is higher under dry cutting condition. 4.2 Analysis of Results from Experiment 2: From figure-3 it is clear that average temperature at tool-work interface by using the NGP cutting fluid higher for all three type cutting speed from MoS 2 fluid and NBA cutting fluid, while temperature in all cutting speed by using NBA cutting fluid lower than MoS 2 cutting fluid. 418 Copyright Vandana Publications. All Rights Reserved.

6 Cutting Tempureture, T ( C) Temperatures Differences among NBA, NGP and MoS 2 based fluid Cooling Cutting Speed, S (rpm) NGP Fluid MoS2 fluid NBA Fluid Figure-3: Shows Temperature differences among NBA, NGP and MoS 2 based fluid cooling From figure-4 shows that the surface roughness of work piece prepared by using Nano graphite fluid (NGP fluid) is higher than surface roughness of work piece prepared using by Nano MoS 2 cutting fluid Higher surface roughness occur due to greater friction because absence of additives between tool and work piece in NBA fluid compare to both NGP fluid and Nano MoS 2 fluid.further study the effect of NBA cutting fluid with addition of NGP cutting fluid and Nano MoS 2 cutting fluid. (a) Surface roughness: Nano MoS 2 fluid (b) Surface roughness: NGP fluid Figure-4: Macroscopic views of surfaces of finished job, using NGP fluid & Nano MoS2 fluid coolants at 550 rpm. 419 Copyright Vandana Publications. All Rights Reserved.

7 4.3 Analysis of Results from Experiment 3: Figure-5 shows that average cutting temperature between tool-work interfaces by using NGP with NBA fluid higher, to the average temperature of interface using MoS 2 with NBA cutting fluid at 550 rpm and 850 rpm cutting speed. Hence MoS 2 with NBA cutting fluid significantly more suitable for sustainable machining. (a)roughness under NGP fluid with NBA (b) Roughness under Nano MoS 2 with NBA Figure-6: Macroscopic view of surfaces of finished jobs, using NGP with NBA & Nano MoS 2 with NBA fluid coolants at 550 rpm. From figure-6 it is clear that the surface roughness of work piece using Nano MoS2 with NBA (Fig.6b) as cutting fluid is best than work piece surface using Nano graphite particle fluid (NGP fluid) (Fig.4b), Nano MoS 2 fluid and NGP with NBA fluid (Fig.6a). V. CONCLUSION Results from the average cutting temperatures and surface roughness verify by the uses of glycerin based liquid fluid, which minimize the 420 Copyright Vandana Publications. All Rights Reserved.

8 temperature compared to dry condition by 20% to 30%. Further studies by the uses of various nanoparticles into glycerin base fluid as NBA, graphite and MoS 2. The temperature reduced in NBA fluid is less than 14% to 21.5% and 2% to 11.6% by Nano graphite and Nano MoS 2 fluid respectively. Further studies on the effect of NBA on Nano graphite fluid and Nano MoS2 fluids in cooling and lubrication. The result shows that average temperature is reduced by Nano MoS 2 with NBA C to 41.5 C which is lower than Nano graphite addition with NBA by 15.26% to 17% and from dry condition 24% to 40%. REFERENCES 1) International Trade Administration, 2007, How does commerce define sustainable manufacturing? U.S. Department of Commerce, 2) A.D Jayal, F. Badurdeen, O.W. Dillon Jr., I.S. Jawahir, 2010, Sustainable manufacturing : Modeling and optimization challenges at the product, process and system levels, Journal of Manufacturing Science and Technology, 2 : ) A. F. Clarens, K. F. Hayes, S. J. Skerlos, 2006, Feasibility of metalworking fluids delivered in supercritical carbon dioxide, Journal of Manufacturing Processes, 8 : ) N. R. Dhar, M. T. Ahmed, S. Islam, 2007, An experiment investigation on effect of minimum quantity lubrication in machining AISI 1040 steel, International Journal of Machine Tools & Manufacture, 5) P. W. Marksberry, I. S. Jawahir, 2008, A comprehensive tool-wear/tool life performance model in the evaluation of NDM (near dry machining) for sustainable manufacturing, International Journal of Machine Tools &Manufacture, 48 : ) Google search Freezing and melting points of some common liquids 7) Thermal conductivities of the elements (data page)- Wikipedia, the free encyclopedia [ the_elements_(data_page] 8) Cutting fluid- Wikipedia, the free encyclopedia (2015) 9) Types of machine coolant (2015) Google search. 10) Manufacturing technology ME 361Manufacturing Sciences J.Ramkumar 11) American elements -The material science manufacturer Boiling points of gases, liquids & solids 12) The Engineering Toolbox Boiling points liquids & gases Copyright Vandana Publications. All Rights Reserved.