International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017
p-ISSN: 2395-0072
www.irjet.net
Influence of Cutting Fluid Condition and Cutting Parameter on Material Removal Rate in Straight Turning Process of En31 Steel Karan A. Katle1, Abhishek Rehpade2, Faruk Qureshi3 1B.E.
(Mechanical Engineering), JD College of Engineering and Management, RTM Nagpur University, Maharashtra, India 2B.E. (Mechanical Engineering), JD College of Engineering and Management, RTM Nagpur University, Maharashtra, India 3B.E. (Mechanical Engineering), JD College of Engineering and Management, RTM Nagpur University, Maharashtra, India ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - In machining process in order to achieve high
productivity, high values of machining parameters are needed resulting in generation of high temperature zones at tool chip interface. In a machining process, high values of machining parameters directly affects material removal rate. Also the generation of high temperature zones at tool chip interface will have an adverse effect on production quality such as poor surface finish, reduction in tool life, etc. The present paper deals with the study of effects of different cutting parameters on material removal rate in straight turning process of En31 steel under different environmental conditions. Key Words: MQL, EN-31, Material Removal Rate, Cutting fluid, Metal cutting, Machining, Carbide Cutting Tool, Wet Machining, Taguchi method.
1. INTRODUCTION Machining is a process of removal of material from a workpiece in order to obtain a product of desired shape. In order to meet the demand of higher productivity, emphasize should be given on development of machining process accordingly. Productivity could be increase by using specific method of production, efforts for reducing cost of production, better surface finish, etc. One of the important factors of increasing productivity is high rate machining parameters. The high rates of machining parameters result in high material removal rates. So, one can directly say high material removal rate results in high productivity. The high material removal rate also results in friction as well as generation of high temperature zones at tool chip interface. The generation of high temperature zones results in poor surface finish, softening of tool material due to which tool wears out at a faster rate resulting in reduction in tool life. Use of appropriate cutting fluid during machining may help to eliminate such problem. It was found that using cutting fluid during machining operation results in reduction in generation of high temperature zones, followed by good surface finish as well as less tool wear. Lubrication not only offers cooling of high temperature zones, in addition to this, they also provide sufficient time for Š 2017, IRJET
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Impact Factor value: 5.181
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tool and workpiece to get cool down and maintain them at ambient conditions ensuring reduction in error of size caused due to thermal expansion of workpiece, preventing dimensional transformation and maintaining good surface finish as well as dimensional accuracy. As each advantage has a disadvantage too, conventional used of cutting fluids were found to be hazardous for humans as well as environment resulting in skin infections followed by various types of diseases. Also introducing large amount of cutting fluid at tool chip interface resulting in bounce back of the major part of cutting fluid from the external surface and thus proper cooling of tool chip interface cannot be ensured. It is estimated that the cost of cutting fluid is 7%-17% range of total cost in industry. Thus increased rate of cutting fluid will adversely affect the working capital of the industry. So an alternative is needed for which can serve the purpose of cutting fluid applied in flooded condition. The various cooling techniques are available such as flood cooling, solid lubricant, high pressure cooling, cryogenic cooling and minimum quantity lubrication each having some advantage as well as disadvantage too. Flood machining is technique in which cutting fluid is used in enormous quantity. This has advantages of low temperature generation, better surface finish and less tool wear. But the major disadvantage behind using such technique is cost of cutting fluid, disposal and environment problems as well as health hazards caused due to it. Application of lubricant in solid form is solid lubrication. It delivers efficient boundary lubrication, improving friction and minimizing wear in extreme operation environment. It results in high temperature stability and high load carrying capacity with disadvantages such as poor heat dissipation properties, poor self healing properties. High pressure cooling is an emerging technique that delivers high pressured fluid to the tool and machined material resulting in better penetration of cutting fluid in tool chip in
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cutting zone for
cooling purpose. ISO 9001:2008 Certified Journal
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