The document discusses an analysis of machining parameters in turning operations using minimum quantity lubrication (MQL). MQL uses much less cutting fluid compared to conventional flooding lubrication. The study aims to measure surface roughness, tool wear, and cutting temperature under dry, flooded, and MQL conditions. Various machining parameters like cutting velocity, feed rate, and depth of cut are investigated. Preliminary results found that MQL reduced average cutting temperature by 5-10% compared to dry and flooded conditions. MQL also showed lower tool wear and better surface finish outcomes than dry machining. The results suggest MQL can improve machining performance over conventional flooded lubrication.
Analysis of machining parameters using MQL condition
1. ANALYSIS OF MACHINING PARAMETERS IN TURNING
OPERATION IN MQL CONDITION
GUIDED BY:
Mr. Deepak Suna
Asst. Professor
Dept. of Production Engineering
PRESENTED BY :
Swati Kanungo- 36939
Sweta Laxmi Rout- 36965
Padmalochan Nanda- 36926
Sisir Kumar Barik- 36957
Aravind Biswal- 36941
Sagar Dash- 36929
Ranjit Behera- 36954
INDIRA GANDHI INSTITUTE OF TECHNOLOGY,
SARANG
A MAJOR PROJECT ON
2. CONTENTS
INTRODUCTION
PURPOSE
LITERATURE REVIEW
OBJECTIVE
MATERIAL SELECTION
METHODOLOGY
MQL IN TURNING OPERATION
RESULTS AND DISCUSSION
CONCLUSION
WORKING VIDEO OF MQL
FUTURE SCOPE
REFERENCE
3. INTRODUCTION
MACHINING IS THE WIDE SPREAD METAL SHAPING PROCESS, IT CONSIST RAPID WEAR RATE
OF CUTTING TOOLS DUE TO HIGH CUTTING TEMPERATURE GENERATED DURING THE
PROCESS. THUS EFFECTIVE CONTROL OF THE HEAT GENERATED DURING MACHINING IS
ESSENTIAL TO ENSURE GOOD WORK QUALITY. DIFFERENT CUTTING FLUIDS ARE APPLIED TO
AVOID THE PROBLEM; HOWEVER CONVENTIONAL CUTTING FLUIDS ARE RESTRICTED DUE TO
THEIR HARMFUL HEALTH AND ENVIRONMENTAL IMPACTS.
THE NECESSITY TO MACHINE USING LESS HARMFUL CUTTING FLUIDS HAS LED THE
RESEARCHER TO DEVELOP NEW CUTTING FLUIDS WHICH ARE LESS HARM AND THE RESULT
OF INVESTIGATION CAME UP WITH A NEW SYSTEM CALLED MINIMUM QUANTITY LUBRICATION
(MQL)
MINIMUM QUANTITY LUBRICATION REFERS TO USE SMALL AMOUNT OF CUTTING FLUID,
WHICH IS ABOUT 1000 TIMES LESS THAN THAT OF CONVENTIONAL CUTTING FLUIDS.
4. LUBRICATION IS THE PROCESS OR TECHNIQUE OF USING A LUBRICANT TO
REDUCE FRICTION AND WEAR & TEAR IN A CONTACT BETWEEN TWO SURFACES.
MQL: IT IS A PROCESS OF PROVIDING LUBRICANT IN VARIOUS MACHINING
PROCESS IN MINIMUM QUANTITY.
DUE TO MINIMUM QUANTITY LUBRICATION, LUBRICATING FLUID CAN BE REDUCED
SIGNIFICANT TIMES THAN CONVENTIONAL LUBRICATION PROCESS.
THE INTERFACE BETWEEN TOOL AND WORKPIECE IS COATED WITH HIGH QUALITY
OF LUBRICANT THAT IS DELIVERED IN ATOMIZED SPRAY TO ACHIEVE LUBRICATION
PROPERTIES.
WHAT IS MQL?
5. PURPOSE
IN ALL MACHINING PROCESSES, TOOL WEAR IS A NATURAL PHENOMENON AND IT
LEADS TO TOOL FAILURE.
THE GROWING DEMANDS FOR HIGH PRODUCTIVITY OF MACHINING NEED USE OF
HIGH CUTTING VELOCITY AND FEED RATE.
SUCH MACHINING INHERENTLY PRODUCES HIGH CUTTING TEMPERATURE,
WHICH NOT ONLY REDUCES TOOL LIFE BUT ALSO IMPROVES THE PRODUCT
QUALITY.
METAL CUTTING FLUIDS CHANGES THE PERFORMANCE OF MACHINING
OPERATIONS BECAUSE OF THEIR LUBRICATION, COOLING, AND CHIP FLUSHING
FUNCTIONS BUT THE USE OF CUTTING FLUID HAS BECOME MORE PROBLEMATIC
IN TERMS OF BOTH EMPLOYEE HEALTH AND ENVIRONMENTAL POLLUTION.
6. THE OTHER ADVANTAGE OF STUDYING THE VARIOUS MACHINING PROCESS USING
MQL SYSTEM IS TO :
EASILY AVAILABLE AND LOW COST TECHNOLOGY.
NEED OF SUCH IMPROVED SYSTEM IN THIS GENERATION.
DEVELOP TECHNICAL SKILLS.
IMPROVE MACHINING CHARACTERISTICS.
UTILIZE NATURAL RESOURCES IN LUBRICATION FIELD.
PROVIDE POLLUTION FREE LUBRICANTS FOR THE INDUSTRIES .
7. TYPES OF LUBRICATION
BASICALLY THERE ARE THREE TYPES OF LUBRICATION
SYSTEMS
FLOODED LUBRICATION
DRY LUBRICATION
MINIMUM QUANTITY
LUBRICATION
8. DRY LUBRICATION :
DRY LUBRICATION IS LUBRICATION IN WHICH USE OF CUTTING OIL IS TOTALLY
PROHIBITED. THIS TYPES OF LUBRICATION IS GENERALLY USED WHERE MATERIAL
REMOVAL RATE IS VERY LESS.
FLOODED TYPE:
FLOODED TYPE OF LUBRICATION SYSTEM IS WHAT WE SEE REGULARLY IN OUR
INDUSTRIES.IN FLOODED TYPE OF LUBRICATING SYSTEM ,LARGE AMOUNT OF
CUTTING FLUID IS SUBJECTED TOWARDS THE WORKPIECE FOR ITS COOLING
ACTIONS .
MINIMUM QUANTITY LUBRICATION (MQL):
THE LUBRICATION TECHNIQUE USES MUCH LESS AMOUNT TO CUTTING FLUID AS
COMPARED TO COVENTIONAL SYSTEM.
9. LITERATURE REVIEW
SL NO. AUTHOR YEAR JOURNAL
NAME
FINDINGS
1 N.R. Dhar ,
M.amruzzaman,
Mahiuddin
Ahmed
2005 Effect of
minimum quantity
lubrication (MQL)
on tool wear
and surface
roughness in
turning AISI-4340
steel
Material:- Aisi-4340-steel
PARMAETERS:-Tool wear , surface roughness
CUTTING TOOL:- Carbide
Findings:-The cutting performance of MQL machining is
better than that of dry and conventional machining with flood
cutting
fluid supply because MQL provides the benefits mainly
by reducing the cutting temperature, which improves the
chip–tool interaction and maintains sharpness of the cutting
edges.
2 B. Tasdelena,
T. Wikblomb,
S. Ekeredc
2007 Studies on
minimum quantity
lubrication (MQL)
and air cooling at
drilling
Drill body:-Coro drill 880-D1900L25-03
Inserts:- GM 1044 (centrum), GM 4024 (periphery)
Cutting speed:-155m/min
Feed rate:-0.11mm/rev
Hole depth:-33mm
Findings:-
• The highest wear both for center and periphery inserts was
observed using emulsion, followed by air and MQL assisted
machining.
• The highest cooling ability of emulsion is probably the
reason
for the excessive tool wear located in the middle of the
10. 3 M.M.A. Khana,
M.A.H. Mithua,
N.R. Dharb
2007 Effects of
minimum quantity
lubrication on
turning AISI 9310
alloy
steel using
vegetable oil-
based cutting fluid
Material:- AISI 9310 steel
Machine tool:- Lathe Machine, 15 hp
CUTTING TOOL:- Uncoated carbide, SNMG 120408 (P-30
grade)
Findings:- MQL provided significant improvements expectedly,
though in varying degree, in respect of chip formation modes,
tool wear and surface finish throughout the range of Vc and so
undertaken mainly due to reduction in the average chip–tool
interface temperature.
Wet cooling by soluble oil could not control the cutting
temperature appreciably and its effectiveness decreased further
with the increase in cutting velocity and feed rate.
4 Murat Sarıkaya,
Abdulkadir Güllü
2006 Multi-response
optimization of
minimum quantity
lubrication
parameters using
Taguchi-based grey
relational analysis in
turning
of difficult-to-cut
alloy Haynes 25
Inserts:- Uncoated carbide, SNMG 120408-QM (S-15 grade)
Cutting speed:-155m/min
Cutting speed (Vc) :-30, 40, 50 m/min
Feed rate (f):- 0.15 mm/rev
Depth of cut :- 1mm
Material removal rate (MRR):-7500 mm3
Tool Holder :- PSBNR2020K12
Findings:- The highest wear both for center and periphery
inserts was observed using emulsion, followed by air and MQL
assisted
machining.
The highest cooling ability of emulsion is probably the reason
for the excessive tool wear located in the middle of the
contact zone.
11. OBJECTIVE
IN THIS PROJECT WE ARE GOING TO INVESTIGATE THE ROLE OF MQL ON
TOOL WEAR AND SURFACE ROUGHNESS IN TURNING OPERATION AT
INDUSTRIAL SPEED-FEED COMBINATION.
AIM OF THIS EXPERIMENT IS TO MEASURE SURFACE ROUGHNESS, TOOL
WEAR AND CUTTING TEMPERATURE IN DRY CONDITION , FLOODED
CONDITION AND MQL CONDITION.
12. MATERIAL SELECTION
LUBRICANT: LUBRICANT OIL- 40 GRADE
MATERIAL: 6061 ALUMINIUM ALLOY, Ø25.7 × 150mm
DENSITY OF 6061 ALUMINIUM ALLOY – 2.7 g/cm3
CUTTING TOOL(INSERT): HSS
MACHINE: LATHE , PATHAK INDUSTRIES
OPERATION: TURNING
CUTTING ENVIRONMENT: DRY, FLOODED, MQL
COMPONENT Al Si Mg Cr Cu
COMPOSITION (Wt.
%)
97.9 0.6 1.0 0.2 0.28
6061 Al Alloy
14. METHODOLOGY
THE MQL NEEDS TO BE SUPPLY AT HIGH PRESSURE AND IMPINGED AT HIGH SPEED
THROUGH THE NOZZLE AT THE CUTTING ZONE. CONSIDERING THE CONDITIONS
REQUIRED FOR THE PRESENT EXPERIMENTAL WORK AN UNINTERRUPTED SUPPLY
OF MQL AT CONSTANT PRESSURE OVER A REASONABLY LONG CUT . A MQL
DELIVERY SYSTEM WILL BE DESIGNED, FABRICATED AND USED. THE SCHEMATIC
VIEW OF THE MQL SET UP IS SHOWN IN FIG. 1
THE THIN BUT HIGH VELOCITY STREAM OF MQL WILL PROJECTED FROM A NOZZLE
ALONG THE CUTTING EDGE OF THE INSERT, AS INDICATED IN A FRAME WITHIN FIG.
1 , SO THAT THE COOLANT REACHES AS CLOSE TO THE CHIP–TOOL AND THE
WORK–TOOL INTERFACES AS POSSIBLE.
16. THE REFERENCE PHOTOGRAPHIC VIEW OF THE EXPERIMENTAL SET-UP IS SHOWN
IN FIG. 2. & FIG. 3 THE MQL JET WILL BE USED MAINLY TO TARGET THE RAKE AND
FLANK SURFACE AND TO PROTECT THE AUXILIARY FLANK TO ENABLE BETTER
DIMENSIONAL ACCURACY.
MQL IS EXPECTED TO PROVIDE SOME FAVOURABLE EFFECTS MAINLY THROUGH
REDUCTION IN CUTTING TEMPERATURE. THE SIMPLE DIGITAL THERMOMETER WILL
EMPLOYED TO MEASURE THE AVERAGE CUTTING TEMPERATURE DURING TURNING
AT DIFFERENT VC COMBINATIONS BY THE HSS INSERT UNDER DRY, WET AND MQL
CONDITIONS.
ROUGHNESS TESTER WILL BE EMPLOYED TO MEASURE THE SURFACE
ROUGHNESS OF THE MACHINED WORKPIECE OF DRY, FLOODED & MQL CONDITION
AND CUTTING FORCE WILL BE MEASURED BY USING DYNAMOMETER.
17. MQL IN TURNING OPERATION
TURNING IS A MACHINING PROCESS IN WHICH NON-ROTARY CUTTING TOOL
DESCRIBES HELICAL PATH WHILE THE WORKPIECE ROTATES.
THE EFFECTS OF CUT, FEED RATE AND CUTTING SPEED WERE STUDIED FOR THE
TOOL WEAR AND SURFACE FINISH.
MIXING
CHAMBER
Fig-2
OUTLET
INLET (2)
COMPRESSOR
19. EXPERIMENTAL INVESTIGATION
EXPERIMENTS HAVE BEEN CARRIED OUT BY PLAIN TURNING A 25.7MM DIAMETER
AND 150MM LONG ROD OF ALLUMINIUM IN A POWERFUL AND RIGID LATHE
(PATHAKMACHINE COMPANY) AT INDUSTRIAL SPEED-FEED COMBINATION UNDER
DRY, WET AND MINIMUM QUANTITY LUBRICATION CONDITIONS.
THE EXPERIMENTAL CONDITIONS ARE GIVEN IN Table-1
22. EFFECT ON CUTTING TEMPERATURE
DURING MACHINING OF ANY DUCTILE MATERIALS, HEAT IS GENERATED AT THE (I)
PRIMARY DEFORMATION ZONE DUE TO SHEAR AND PLASTIC DEFORMATION, (II)
CHIP–TOOL INTERFACE DUE TO SECONDARY DEFORMATION AND SLIDING AND (III)
WORK–TOOL INTERFACES DUE TO RUBBING.
ALL SUCH HEAT SOURCES PRODUCE MAXIMUM TEMPERATURE AT THE CHIP–TOOL
INTERFACE, WHICH SUBSTANTIALLY INFLUENCE THE CHIP FORMATION MODE,
CUTTING FORCES AND TOOL LIFE. CONVENTIONAL CUTTING FLUID APPLICATION
MAY, TO SOME EXTENT, COOL THE TOOL AND THE JOB IN BULK BUT CANNOT COOL
AND LUBRICATE EFFECTIVELY AT THE CHIP–TOOL INTERFACE WHERE THE
TEMPERATURE IS MAXIMUM.
23. IT WAS OBSERVED THAT THE MQL JET IN ITS PRESENT WAY OF APPLICATION
ENABLED REDUCTION OF THE AVERAGE CUTTING TEMPERATURE BY ABOUT 5–10%
DEPENDING UPON THE LEVELS OF THE PROCESS PARAMETERS.
EVEN SUCH APPARENTLY SMALL REDUCTION IN THE CUTTING TEMPERATURE IS
EXPECTED TO HAVE SOME FAVOURABLE INFLUENCE ON OTHER MACHINABILITY
INDICES.
THE EXPERIMENTAL OBSERVED DATA WAS PRESENTAED IN GRAPHICAL FORM .
25. EFFECT ON TOOL WEAR
DURING MACHING, CUTTING TOOLS REMOVES MATERIAL FROM THE COMPONENT
TO ACHIEVE THE REQUIRED SHAPE, DIMENSION AND SURFACE
ROUGHNESS(FINISH). HOWEVER WEAR OCCUR DURING THE CUTTING ACTION, AND
IT ULTIMATELY RESULT IN THE FAILURE OF THE CUTTING TOOL.
THE CHANGE OF SHAPE OF THE TOOL FROM ITS ORIGINAL SHAPE , DURING
MACHINING, RESULTING FROM GRADUAL LOSS OF TOOL MATERIAL .THIS IS KNOWN
AS TOOL WEAR IN MACHINING.
ANOTHER IMPORTANT TOOL WEAR CRITERIA IS AVEARGE AUXILIARY FLANK WEAR
WHICH GOVERNS THE SURFACE FINISH ON THE JOB AS WELL AS DIMENSIONAL
ACCURACY. IRREGULAR AND HIGHER AUXILIARY FLANK WEAR LEADS TO POOR
SURFACE FINISH AND DIMENSIONAL INACCURACY. THE APPLICATION MQL HAS
EXPECTED TO PROVIDE BETTER SURFACE FINISH.
26. THE TOOL WEAR IS MORE ON DRY CONDITION AND GRADUALLY DECREASE IN
FLOODED AND MQL CONDITION.THE REASON BEHIND IT IS REDUCTION IN
TEMPERATURE, BECAUSE OF THAT GROWTH OF TOOL WEAR DECREASES AND TOOL
LIFE WOULD INCREASES OR MUCH HIGHER IF MQL IS PROPERLY APPLIED.
USUALLY UNDER DRY ENVIRONMENTS ABRASIVE SCRATCH MARKS APPEARED IN
THE INSERT, THERE MAY BE SOME PLASTIC DEFORMATION OCCUR UNDER SAME
CONDITION WHICH IS REDUCED UNDER APPLICATION OF FLOODED AND MQL
nitial wt. of
tool=69.70g
Final wt. of
tool=69.41g
Initial wt. of
tool=69.41g
Final wt. of
tool=69.37g
Initial wt. of
tool=69.37g
Final wt. of
tool=69.34g
DRY CONDITION FLOODED CONDITION MQL CONDITION
27. EFFECT ON SURFACE ROUGHNESS
ROUGHNESS IS A MEASUREMENT OF THE SMALL SCALE VARIATION IN THE HEIGHT
OF PHYSICAL SURFACE. IT CONSIST OF SURFACE IRREGULARITIES WHICH
RESULTS FROM THE VARIOUS MACHINING PROCESS. THESE IRREGULARITY
COMBINE TO FORM SURFACE TEXTURE.
THIS IS IN CONTRAST OF LARGE SCALE VARIATIONS, WHICH MAY BE EITHER PART
OF THE GEOMETRY OF THE SURFACE OR UNWANTED ‘WAVINESS’.
SURFACE FINISH IS AN IMPORTANT INDEX OF MACHINABILITY BECAUSE
PERFORMANCE AND SERVICE LIFE OF MACHINED COMPONENTS ARE OFTEN
AFFECTED BY SURFACE FINISH AND EXTENT OF RESIDUAL STRESS & PRESSURE
PRESENT ON SURFACE.
28.
29. THE MAJOR CAUSE BEHIND DEVELOPMENT OF SURFACE ROUGHNESS IN
CONTINUOUS MACHINING PROCESS LIKE TURNING OF DUCTILE MATERIAL ARE:
i. REGULAR FEED MARKS LEFT BY THE TOOL TIP ON THE FINISHED SURFACE .
ii. IRREGULAR DEFORMATION OF THE AUXILIARY CUTTING EDGE AT THE TOOL
TIP DUE
TO CHIPPING, FRACTURING AND WEAR.
iii. VIBRATION ON MACHINING SYSYTEM.
iv. BUILT-UP-EDGE FORMATION.
IN MQL CONDITION TOOL/FLANK WEAR ON AUXILIARY CUTTING EDGE IS REDUCED,
SO SURFACE ROUGHNESS IS EXPECTED TO INCREASE UNDER MQL CONDITION.
30. CONCLUSIONS
BASED ON THE PRESENT EXPERIMENTAL INVESTIGATION THE
FOLLOWING CONCLUSIONS CAN BE MADE:
THE CUTTING PERFORMANCE OF MQL-MACHINING IS BETTER THAN THAT OF DRY AND
CONVENTIONAL MACHINIG ALSO THE MACHINABILITY OF THE WORK HAS A SIGNIFICANT
IMPROVED.
MQL PROVIDE BENEFITS MAINLY BY REDUCING THE CUTTING TEMPERATURE, WHICH
IMPROVES THE CHIP TOOL INTERACTION AND MAINTAINS THE WORK CONDITION EASE FOR
FURTHER MACHINING.
MQL JET PROVIDE REDUCED TOOL WEAR , IMPROVED TOOL LIFE AS COMPARED TO DRY AND
FLOODED CONDITION.
MQL IMPROVES AND ENHANCES THE PRODUCTIVITY AND REDUCED THE COST OF COOLANT
ALLOWING HIGHER CUTTING VELOCITY AND FEED.
31. Final machined workpiece
a b
c
a. DRY CONDITION
b. FLOODED CONDITION
c. MQL CONDITION
Dt. 11/04/2021
Dt. 11/04/2021
MT LAB (PE
DEPT.)
33. FUTURE SCOPE
MQL TECHNOLOGY HAS A GREAT POTENTIAL TO PERFORM WELL IN THE EXPERIMENTAL
ENDEAVOR, HERE, WE FOUND A FEW GAPS IN THE PREVIOUS LITERATURE AND PROPOSE
THESE GAPS AS THE FUTURE SCOPE OF THE STUDY, WHICH IS LISTED BELOW:
INTRODUCTION OF NANO PARTICLES IN LUBRICATION PROCESS AND NEW DEVELOPMENT OF MQL
TECHNOLOGY USING NANOFLUIDS FOR SUSTAINABLE CUTTING PROCESSES HAS A POTENTIAL
FOR FUTURE STUDIES.
A FIELD SURVEY IS REQUIRED TO BE PUBLISHED ON THE ACTUAL INDUSTRIAL APPLICATION OF
MQL. FOR THIS PURPOSE, THE LIFE CYCLE ASSESMENT WOULD BE A GOOD CHOICE.
STUDY OF THE DROPLET DYNAMICS OF MQL BASE FLUID WILL BE A NEW RESEARCH DIMENSION.
HERE, THE THERMAL ANALYSIS NEEDS TO BE INCORPORATED WITH SUSTAINABILITY ANALYSIS
FOR GREEN MANUFACTURING TECHNOLOGY.
LASTLY, THE ADVENT OF ADVANCED COMPUTATIONAL ALGORITHMS AND DATA SCIENCE DEMAND
TO BE INTEGRATED WITH MQL ASSISTED MACHINING, AND MQL CONTROL PARAMETERS SO THAT
INTELLIGENT AND SMART MANUFACTURING CAN BE DEVISED FOR INDUSTRY 4.0. STUDIES ARE
REQUIRED IN THIS FIELD.
34. REFERENCES
Studies on minimum quantity lubrication (MQL)and air cooling at drilling. B. Tasdelena,∗, T. Wikblomb,
S. Ekeredc
Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using vegetable oil-based
cutting fluid. M.M.A. Khana,∗, M.A.H. Mithua, N.R. Dharb
Multi-response optimization of minimum quantity lubrication parameters using Taguchi-based grey
relational analysis in turning of difficult-to-cut alloy Haynes. 25 Murat Sarıkaya a, *, Abdulkadir Güllü b
Comparison among different vegetable fluids used in minimum quantity lubrication systems in the
tapping process of cast aluminum alloy Sergio Luiz Moni Ribeiro Filho, Jessica Tito Vieira, Juliano
Aparecido de Oliveira, Etory Madrilles Arruda, Lincoln Cardoso Brand~ao*
Experimental evaluation of the lubrication performance of mixtures of castor oil with other vegetable
oils in MQL grinding of nickel-based Alloy Shuming Guo, Changhe Li*, Yanbin Zhang, Yaogang Wang,
Benkai Li, Min Yang, Xianpeng Zhang, Guotao Liu
Study of specific energy and friction coefficient in minimum quantity lubrication grinding using oil-
based nanolubricants Parash Kalita a, Ajay P. Malshea,∗, S. Arun Kumarb, V.G. Yoganathb, T.
Gurumurthyb