Analysis of machining parameters using MQL condition

ANALYSIS OF MACHINING PARAMETERS IN
TURNING OPERATION IN MQL CONDITION
A thesis submitted in partial fulfilment of requirements for the award of degree
of
“BACHELOR OF TECHNOLOGY”
IN
PRODUCTION ENGINEERING
By
SWATI KANUNGO (Regd. No.: 1701105420)
SWETA LAXMI ROUT (Regd. No.: 1821105178)
PADMALOCHAN NANDA (Regd. No.:1701105176)
SISIR KUMAR BARIK (Regd. No.: 1821105135)
ARAVIND BISWAL (Regd. No.: 1821105022)
SAGAR DASH (Regd. No.: 1701105606)
RANJIT BEHERA (Regd. No.: 1821105114)
Under the supervision of
MR. DEEPAK SUNA
(ASSISTANT PROFESSOR)
DEPARTMENT OF PRODUCTION ENGINEERING
INDIRA GANDHI INSTITUTE OF TECHNOLOGY,
ODISHA, SARANG-759146
JUNE, 2021

CERTIFICATE OF RECOMENDATION
This is to certify that the thesis entitled “ANALYSIS OF MACHINING
PARAMETERS IN TURNING OPERATION IN MQL CONDITION” has
been prepared under my supervision by the group of following members and
accepted in partial fulfilment of the requirements for the degree of Bachelor of
Technology in Production Engineering. They have taken keen interest in
completing the dissertation. I found that they are sincere, hard working, and
their performances are excellent.
I wish them all the luck in their future endeavour.
Dr. B.B.Choudhury Mr. Deepak Suna
Head of the Department Supervisor
Department of Production Department of Production
Engineering Engineering
IGIT, SARANG IGIT, SARANG

CERTIFICATE OF APPROVAL
This is to certify that we have examined the thesis entitled “ANALYSIS OF
MACHINING PARAMETERS IN TURNING OPERATION IN MQL
CONDITION” submitted by the group of following members, towards partial
fulfilment for the award of degree of Bachelor of Technology of Indira
Gandhi Institute of Technology, Sarang, Odisha. We hereby accord out
approval of it as a thesis work carried out and presented in a manner required
for its acceptance for the partial fulfilment for the award of degree of Bachelor
of Technology in Production Engineering for which it has been submitted. The
approval does not necessarily endorse or accept every statement made, opinion
expressed or conclusions drawn as recorded in this thesis. It only signifies the
acceptance of the thesis for the purpose it has been submitted.
(Internal Examiner) (External Examiner)

CERTIFICATE OF SUBMISSION
This is certify that the thesis entitled “ANALYSIS OF MACHINING
PARAMETERS IN TURNING OPERATION IN MQL CONDITION” has
been submitted by the group of following members, accepted in partial
fulfilment of the requirements for the award of degree of Bachelor of
Technology in Production Engineering during session (2017-2021).
Swati Kanungo-(1701105420)
Sweta Laxmi Rout- (1821105178)
Padmalochan Nanda-(1701105176)
Sisir Kumar Barik- (1821105135)
Aravind Biswal- (1821105022)
Sagar Dash- (1701105606)
Ranjit Behera-(1821105114)
Mr. Deepak Suna Dr. B.B.Choudhury
(Assistant Professor) Countersigned by
Head of Department

DECLARATION
This thesis entitled “ANALYSIS OF MACHINING PARAMETERS IN
TURNING OPERATION IN MQL CONDITION” being submitted by us, is
an original work of research to the best of our knowledge the matter embodied
in this thesis work has not been submitted to any Universities/Institutes for the
award of degree.
DATE- 06.06.21 Padmalochan Nanda-(1701105176)
PLACE- IGIT, SARANG. Sisir Kumar Barik- (1821105135)
Sagar Dash- (1701105606)

ACKNOWLEDGEMENT
The highest happiness that accompanies the successful completion of any task would be
incomplete without the expression of gratitude to all those people who have helped us
throughout.
We take this opportunity to express our profound gratitude and deep regards to our guide
Mr. Deepak Suna, Assistant Professor of IGIT, Sarang for his exemplary guidance,
monitoring, constant encouragement and kind cooperation throughout the period of work
which has been instrumental in the success of this report.
We would be obliged to avail this opportunity to express profound sense of gratitude to
Name of other faculty helped you, Assistant/Associate/Professor of IGIT, Sarang for
giving us the opportunity to carry out the work efficiently and effortlessly.
We hereby express sincere thanks to all the people who are involved either directly or
indirectly, for their constant support and encouragement without which this project report
would not be possible.
Padmalochan Nanda-(1701105176)
06.06.2021 Sisir Kumar Barik- (1821105135)
Sagar Dash- (1701105606)
i

ABSTRACT
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 impairs 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. The minimization of cutting fluid leads to economical
benefits by way of saving lubricant costs and workpiece/tool/machine cleaning cycle time.
The concept of minimum quantity lubrication (MQL) has used as a means of addressing the
issues of environmental intrusiveness and occupational hazards associated with the airborne
cutting fluid particles on factory shop floors.
In this project an investigation is done related to the role of MQL on tool wear and surface
roughness in turning operation at industrial speed-feed combination.
Key words: MQL(Minimum Quantity Lubrication); Turning; Steel; Tool wear and surface roughness
ii

CONTENTS
Page No.
ACKNOWLEDGEMENT i
ABSTRACT ii
CONTENTS iii,iv
LIST OF FIGURES v
LIST OF TABLES vi
CHAPTER 1: INTRODUCTION 1
1.1
1.2
1.3
Introduction
Purpose
Types of Lubrication
2
5
5
CHAPTER 2: LITERATURE REVIEW 6
2.1 Introduction 7
2.2 Literature Review 8
2.2 Research Gap 11
2.3 Objectives 12
2.4 Problem statement 12
iii

CHAPTER 3: EXPERIMENTAL PROCEDURE 13
3.1 Introduction 14
3.2 Material Selection 15
3.3 Material Investigation 16
3.4 Experimental Setup 17
3.5 Experimental Investigation 22
3.6 Instrumental Review 23
CHAPTER 4: METHODOLOGY 27
4.1 Introduction 28
4.2 Methodology 28
CHAPTER 5: RESULTS AND DISCUSSIONS 29
5.1 Effect on Cutting Tool 30
5.2
5.3
Effect on Tool Wear
Effect on Surface Roughness
31
32
CHAPTER 6: CONCLUSIONS 34
6.1 Conclusions 35
6.2 Future Scope 36
REFERENCES 37
iv

LIST OF FIGURES
Figure
No.
Name Page
No.
1.1
3.1
3.2
3.3
3.4
3.5
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
5.1
5.2
5.3(a),(b)
Machine view in MQL condition.
Schematic view of Mixing Chamber
Schematic view of MQL unit.
MQL Technique
The photographic view of Mixing Chamber setup.
The photographic view of the experimental set-up
Weighing machine
Vernier calliper
Electronic thermometer
Metal cutting machine
Surface Roughness tester
Thermocouple
A graphical representation between cutting
temperature & cutting velocity in three different
conditions.
Surface Roughness
Final machined work piece
4
15
17
18
19
20
23
24
24
25
26
26
30
32
33
v

LIST OF TABLES
Table
No.
Name Page
No.
3.2
3.4
3.5
5.2
Composition table
Experimental condition table
Experimental table
Tool wear condition table
15
21
22
31
vi

2
Chapter No.1
Introduction
1.1. Introduction
In manufacturing industries, machining processes such as turning is commonly used to
obtain the desired size, shape, and surface of a material through the removal of material
from a work piece. During the turning operation, significant amount of heat is generated
at the tool-chip interface due to friction and stresses generated from the shearing of chips.
The heat generated at the cutting zone contributes to the tool wear of the cutting tool and
has a negative effect on the surface roughness and surface finish. Chip formation is a
machining criterion that is important in order to assess the cutting performance. In order
to lower the temperatures at the cutting zone, lubricants or cutting fluids are widely used
in the manufacturing industry for cooling and lubricating the tool-workpiece interface.
The most common method of applying cutting fluids in turning process is by flood
cooling.
However, the usage of flood coolant has several harmful effects, namely environmental
pollution if mishandled and high costs associated with flood machining. It is stated that
“the coolants and lubricants used for machining represents 16% to 20% of the
manufacturing costs”. Thus, it is vital to find a way to manufacture products using more
sustainable techniques, which would minimize the use of cutting fluids and promote a
healthy and safe working environment. Minimum Quantity Lubrication (MQL), is an
efficient cooling method that is more environmentally friendly compared to flood coolant
while retaining the positive benefits of conventional cooling. Aluminium alloys are
commonly used in automobile and aerospace industries due to its excellent material
properties, which include its high strength to weight ratio, excellent corrosion resistance
and excellent thermal conductivity. In this study, a newly designed cost effective MQL
setup was developed for the turning operation. The effects of different process parameters
(depth of cut and cutting speeds) and cutting environments (Dry, Wet and MQL) on the
tool wear, surface roughness and chip formation in turning Aluminium alloy 6061 were
investigated.

3
High production machining of steel inherently generates high cutting zone temperature.
Such high temperature causes dimensional deviation and premature failure of cutting
tools. It also impairs the surface integrity of the product by inducing tensile residual
stresses and surface and subsurface micro cracks in addition to rapid oxidation and
corrosion. In high speed machining, conventional cutting fluid application fails to
penetrate the chip–tool interface, and thus cannot remove heat effectively. Addition of
extreme pressure additives in the cutting fluids does not ensure penetration of coolant at
the chip–tool interface to provide lubrication and cooling. However, high-pressure jet of
soluble oil, when applied at the chip–tool interface, could reduce cutting temperature and
improve tool life to some extent.
Also the advantages caused by the cutting fluids have been questioned lately, due to the
several negative effects they cause.
When inappropriately handled, cutting fluids may damage soil and water resources,
causing serious loss to the environment. Therefore, the handling and disposal of cutting
fluids must obey rigid rules of environmental protection. On the shop floor, the machine
operators may be affected by the bad effects of cutting fluids, such as by skin and
breathing problems. For the companies, the costs related to cutting fluids represent a large
amount of the total machining costs.
Several research workers state that the costs related to cutting fluids are frequently higher
than those related to cutting tools. Consequently, elimination on the use of cutting fluids,
if possible, can be a significant economic incentive. Considering the high cost associated
with the use of cutting fluids and projected escalating costs when the stricter
environmental laws are enforced, the choice seems obvious. Because of them some
alternatives has been sought to minimize or even avoid the use of cutting fluid in
machining operations. Some of these alternatives are dry machining and machining with
minimum quantity lubrication (MQL).
Dry machining is now of great interest and actually, they meet with success in the field of
environmentally friendly manufacturing. In reality, however, they are sometimes less
effective. When higher machining efficiency, better surface finish quality and severe
cutting conditions are required. For these situations, semi-dry operations utilizing very
small amount of cutting lubricants are expected to become a powerful tool and, in fact,
they already play a significant role in a number of practical applications. Minimum

4
quantity lubrication refers to the use of cutting fluids of only a minute amount-typically of
a flow rate of 50–500 ml/h which is about three to four orders of magnitude lower than
the amount commonly used in flood cooling condition. The concept of minimum quantity
lubrication, sometimes referred to as near dry lubrication or micro-lubrication, has been
suggested since a decade ago as a means of addressing the issues of environmental
intrusiveness and occupational hazards associated with the airborne cutting fluid particles
on factory shop floors. The minimization of cutting fluid also leads to economical
benefits by way of saving lubricant costs and workpiece/tool/machine cleaning cycle
time. Significant progress has been made in dry and semidry machining recently, and
minimum quantity lubrication machining in particular has been accepted as a successful
semidry application because of its environmentally friendly characteristics. Dhar also
used this technique in turning process of medium carbon steel and concluded that, in
some cases, a mixture of air and soluble oil has been shown to be better than the overhead
flooding application of soluble oil.
Without cooling and lubrication, the chip sticks to the tool and breaks it in a very short
cutting time. Therefore, in this process, a good alternative is the use of the MQL
technique. The review of the literature suggests that minimum quantity lubrication
provides several benefits in machining. The main objective of the present work is to
experimentally investigate the role of minimum quantity lubrication on tool wear and
surface roughness in turning AISI-4340 steel at industrial speed feed condition by
uncoated carbide insert (SNMM 120408) and compare the effectiveness of MQL with
that of dry and wet machining. The effectiveness, efficiency and overall economy of
machining any work material by given tool depend largely only on the machinability
characteristics of the tool–work material under the recommended condition.
Fig. 1.1: Machine view in MQL condition.

5
1.2. 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.
1.3. TYPES OF LUBRICATION :
Basically there are three types of lubrication systems;
1.3.1 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.
1.3.2 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 work piece
for its cooling actions.
1.3.3 Minimum Quantity Lubrication (MQL) :
The lubrication technique uses much less amount to cutting fluid as compared to
conventional system.

6
CHAPTER No.2
LITERATURE REVIEW

7
Chapter No.2
Literature review
2.1. Introduction:
Machining can be defined as a group of process of removing material from a workpiece in the
form of chips using a cutting tool to obtain the desired shape, size and surface finish.
According to Khan, machinability is evaluated by cutting temperature (influences product
quality and cutting tool performance), mode of chip formation, cutting forces (affects power
requirements), dimensional accuracy, surface finish and tool wear and tool life. During
machining with high cutting speeds and feed rates, high temperatures are generated at the
cutting zone. This causes reduction in tool life by tool wear which will eventually lead to
deviation of dimensional accuracy of the final product.
A review of various machining characteristics during turning was carried out. From the
review, it is found that machinability is evaluated by cutting temperature, chip formation,
cutting forces, dimensional accuracy, surface finish and tool wear. Hence, in this
investigation, the three machinability criteria, tool wear, surface roughness and chip
formation, will be studied in turning. Besides that, a review on the comparison of different
lubrication modes in turning and its effect on machinability indicated that MQL provides
positive machinability characteristics, such as reduced tool wear and reduced surface
roughness and more favourable chip formation, when compared to dry and wet machining.
MQL is also less of an environmental hazard compared to flood coolant, due to the reduced
amount of lubricant used.
Aluminium alloys are widely used in manufacturing industries due to its excellent material
properties. However, Aluminium alloys are difficult to machine, due to its high ductility and
low melting point, which creates problems due to its affinity for bonding of work material on
the cutting edges of the tool in the form of built up edge. Formation of built up edge on tool
edges causes increased tool wear and eventually higher measured surface roughness values of
work piece during machining . Thus, it is essential to study the effects of MQL machining
with Aluminium alloys.

8
2.2. Literature Review
• N.R. Dhar ,M.amruzzaman, Mahiuddin Ahmed (2005) investigated that 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.
• B. Tasdelena, T. Wikblomb, S. Ekeredc (2007) investigated that 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.
• M.M.A. Khana, M.A.H. Mithua, N.R. Dharb (2007) investigated that 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 S0
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.
• N.R. Dhar , M.W. Islam , S. Islam , M.A.H. Mithu (2006) propose study
investigate the influence of MQL on cutting temperature, chip and dimensional
accuracy in turning of AISI1040 steel. The response parameter was compared with
dry and wet machining. Cutting tool used during turning was SNMM120408 along
with tool holder PSBNR2525MI12. For MQL flow rate of fluid was maintained at 60
ml/hr and compressed air pressure at 7 bar. The fluid has been used for lubrication
was soluble oil. From the study it was concluded that MQL provide advantage mainly
by decreasing the cutting temperature which leads to maintain sharpness of the tool.
Dimensional accuracy improved mainly due to reduction of wear at the tool tip with
the help of MQL.
• Hasan & Dwivedi, (2014) investigated that MQL systems enabled reduction in
average chip tool interface temperature up to 10% as compared to wet machining
depending upon the cutting conditions. MQL machining was performed much
superior compared to the dry and wet machining due to substantial reduction in
cutting zone temperature enabling favourable chip formation and chip–tool

9
interaction. It was also seen from the results that the substantial reduction in tool
wears resulted in enhanced the tool life and surface finish.
• Boswell Islam,( 2012) Concluded that air cooling with the use of small amount of
vegetable oils is not a totally dry process it is quite close and therefore is a
sustainable. It also studied the effects of three parameters like cutting speed, feed and
depth of cut upon surface finish during milling operation and found that the surface
finish was improved by 27% and also showed that MQL may be considered to be an
economical and environmentally compatible lubrication technique.
• Y.Kaynak , H.E.Karaca , R.D.Noebe , I.S.Jawahir (2013) propose study compare
the effect of minimum quantity lubrication and dry machining on tool wear during
turning of NiTi shape memory alloy. A DCGT111308HP grade KC5410 cutting tool
insert with TiB2 coating was used in the experiment. The cryogenic coolant was
liquid nitrogen, applied under 1.5 MPA pressure and approximately 10 g/s mass flow
rate. In MQL metalworking lubricant was used at flow rate 60ml/hr and
approximately 0.4 MPA air pressure. From this study it was concluded that cryogenic
cooling was give better result in tool wear compare to dry and minimum quantity
lubrication.
• Ahmadreza Hosseini Tazehkandi, Mohammadreza Shabgard, Farid Pilehvarian
(2015) propose study focuses on the effect of MQL and flooded cooling on cutting
force , tool tip temperature and surface roughness during turning of Inconel 740. For
spray cooling they utilize liquid nitrogen, bio degradable vegetable cutting fluid along
with the compressed air. The cutting tool used during turning was CNMG120404
coated carbide along with tool holder PCBNL2020M12. For flooded cooling flow rate
was maintain at 40 l/hr and for MQL 80ml/hr combine with air pressure of 700
kpa.From the study it was concluded that cutting force , surface roughness and tool tip
temperature during MQL was reduce 34%, 41% and 52% compare to flooded cooling.
• Radoslaw W. Maruda, Grzegorz M. Krolczyk, Eugene Feldshtein, Piotr
Nieslony, Bozena Tyliszczak, Franci Pusavec (2016) studied the effect of minimum
quantity lubrication , dry machining and minimum quantity lubrication with ester
based additives on tool wear during turning of AISI 1045 carbon steel. Cutting tool
insert used during the experimentation was SNUN 120408 coated carbide insert with
grade P25 along with tool holder ISO- CSDBM2020-M12. It was observed that flank

10
wear mainly depend on material removed volume. In comparison of cooling condition
flank wear and crater wear measured maximum in dry machining and then followed
by MQL and MQL with phosphate ester based additives. VBmax was measured 0.6
mm. In the case of small droplet size ( Davg = 8.53µm ) value of VBmax and KT was
reduce by 17% and 10% respectively compare to large droplet size ( Davg = 22.72
µm). The decrease of the KB crater width with the use of minimum quantity
lubrication with ester based additives method compared with dry machining was from
6.2% for a cutting speed of 250 m/min to 22% for cutting speeds of 350 m/min and
450 m/min. KE indicator for cutting speed 250 m/min for all cooling methods not
exceed more than 0.005 mm.
• D.M. D'Addona, Sunil J Raykar (2016) investigate the effect of wiper geometry
insert on surface quality during turning of OHNS steel. In this study two type of
inserts used (a) WNMG060408MT (conventional) (b) WNMG060408WT,
WNMG060404 (wiper geometry). Design of experiment was made with the help of
Taguchi L36 orthogonal array was selected for experiment and analysis was done by
ANOVA. From the ANOVA table it was concluded that for surface roughness feed
rate (p- 0.00) was most significant parameter followed by depth of cut (p 0.04) and
insert (p-0.05). Surface quality was improved by using wiper geometry insert compare
to conventional insert. Optimum value of input parameter nose radius, Cutting speed,
feed rate and depth of cut maintain at 1.25mm, 1200RPM, 0.08 mm/rev and 0.1mm
respectively for better surface quality.
• Tim walker, (2015) investigate the comparison of MQL and wet turning of AISI1045
work material by selecting the optimal cutting parameters, in order to predict the
cutting force and surface roughness and analyzing the effect of cutting parameters on
machinability. In this experiment cutting speed and depth of cut showed opposite
effects on cutting force and surface roughness. This study shows that MQL turning
has more advantages than wet turning. Further investigated the evaluation of near dry
machining effects on gear milling process efficiency & conclude that MQL is causes
of possibility for efficiency increasing reduction in cost improvement of operational
environment.

11
2.3. Research Gap:
➢ According to Muhammad Abas et al 2020,future research responses such as cutting forces
and dimensional accuracy need be investigated.
➢ According to Muhammad Abas et al 2020,further research on the effect of tool nose radius
along with cutting speed, feed rate, and depth of cut need can be incorporated to study its
effect on surface roughness profile, tool life, material removal rate, cutting forces and
dimensional accuracy.
➢ According to B.Tasdelen et al 2019,analysis of the tool–chip contact area with white light
vertical scanning interferometer is a potential method for future works.
➢ According to Banafsheh Sadeghi et al 2019,analysis and modeling of surface roughness,
built-up edge formation, machining forces, effective film thickness of MQL oil at the
interfaces in the contact zone as well as tribochemical reaction effects of MQL on the work
piece material in the cutting zone are the potential methods for future works.
➢ According to Binayak Sen et al 2020, investigation of toxicity of nanoparticles and ionic
liquids is an essential task to increase the application of MQL technology in the near future.
➢ According to Mozammel Mia 2019, in recent times a couple of papers were published
involving the benefits of hybrid nanoparticles and showed that the hybrid nanoparticles are
very useful to improve the lubricity of MQL base fluid. Thus, the authors recommend further
investigation of hybrid nanoparticle-basedMQL technology.
➢ According to G. M. Krolczyk 2021,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.
➢ According to Uttam Kumar Mandal 2019,A field survey is required to be published on the
actual industrial application of MQL.
➢ According to Binayak Sen et al 2020, considering the potential of nanofluids in MQL, more
studies are required to develop the models of tribo-film formation, heat transfer by MQL,
suspension of nanoparticles, wetting ability of sprayed droplets, etc.
➢ According to Sankar Prasad Mondal et al 2020,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.

12
2.4. Objective:
 In this project an investigation is done related to 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, flank wear and machining
time in dry condition, flooded condition and MQL condition.
2.5. Problematic Statement
The challenges that we faced during working on this project is that –
• Difficulty in installation of MQL setup as the pipes which connects the chamber of
water and coolant /lubricant were bit larger so, have to replace it with a smaller
diameter pipe.
• Another difficulty of reverse flow of MQL lubricant from mixing chamber towards
the liquid chamber was faced and it was resolved with a replacement of nozzle head
and pipes.
• Due to the pandemic situation a difficulty for measuring the surface roughness was
faced, as a proper setup or interferometer for checking the surface roughness of the
material was not available. So other resources were applied due to inability of
measuring the surface roughness measurements.
• As there was unavailability of thermocouple which is used to measure the temperature
so was resolved by a digital or electronic thermometer which showed the nearby
temperature.
• Grinding the HSS tool tip to maintain its cutting ability was a great task.
Overall, maintaining all the resources in a right manner with a limited period of time for the
completion of the project during this pandemic situation was quite challenging and
succeeded in achieving it.

13
CHAPTER No.3
EXPERIMENTAL PROCEDURE

14
Chapter No.3
Experimental Procedure
3.1. Introduction:
In this study, a newly designed cost effective MQL setup was developed for the turning
operation. The effects of different process parameters (depth of cut and cutting speeds) and
cutting environments (Dry, Wet and MQL) on the tool wear, surface roughness in turning
Aluminium alloy 6061 were investigated.
During the turning operation, significant amount of heat is generated at the tool-chip interface
due to friction and stresses generated from the shearing of chips. The heat generated at the
cutting zone contributes to the tool wear of the cutting tool and has a negative effect on the
surface roughness and surface finish. Chip formation is a machining criterion that is
important in order to assess the cutting performance. In order to lower the temperatures at the
cutting zone, lubricants or cutting fluids are widely used in the manufacturing industry for
cooling and lubricating the tool-workpiece interface. The most common method of applying
cutting fluids in turning process is by flood cooling. However, the usage of flood coolant has
several harmful effects, namely environmental pollution if mishandled and high costs
associated with flood machining. It is stated that “the coolants and lubricants used for
machining represents 16% to 20% of the manufacturing costs”.
Thus, it is vital to find a way to manufacture products using more sustainable techniques,
which would minimize the use of cutting fluids and promote a healthy and safe working
environment. Minimum Quantity Lubrication (MQL), is an efficient cooling method that is
more environmentally friendly compared to flood coolant while retaining the positive
benefits of conventional cooling. Aluminium alloys are commonly used in automobile and
aerospace industries due to its excellent material properties, which include its high strength to
weight ratio, excellent corrosion resistance and excellent thermal conductivity. The cutting
tools in conventional machining, particularly in continuous chip formation processes like turning,
generally fail by gradual wear by abrasion, adhesion, diffusion, chemi cal erosion, galvanic action,
etc. depending upon the tool–work materials and machining condition. Tool wear initially starts with
a relatively faster rate due to what is called break-in wear caused by attrition and micro chipping at
the sharp cutting edges.

15
MQL IN TURNING OPERATION:
 Turning is a machining process in which non-rotary cutting tool describes helical tool
path while the workpiece rotates.
 The effects of cut, feed rate and cutting speed were studied for the tool wear and
surface finish.
3.2 MATERIAL SELECTION:
 Lubricant: castor oil- 40 grade
 Material: Aluminium 6061 , ø25.7 × 150mm
 MATERIAL SPECIFICATION:
Table 3.1- Composition table
COMPONENT Al Si Mg Cr Cu
COMPOSITION
(Wt.%)
97.9 0.6 1.0 0.2 0.28
Fig.3.1- Schematic view of Mixing Chamber

16
Density of 6061 aluminium alloy – 2.7 g/cm3
 cutting tool(insert): HSS
 machine: lathe, Pathak industries
 operation: turning
 cutting environment: Dry, Wet (flooded condition), MQL
3.3. MATERIAL INVESTIGATION:
The materials that we used are:
1. Aluminium alloy:
Aluminium alloys are widely used in manufacturing industries due to its excellent material
properties. However, Aluminium alloys are difficult to machine, due to its high ductility and
low melting point, which creates problems due to its affinity for bonding of work material on
the cutting edges of the tool in the form of built up edge. Formation of built up edge on tool
edges causes increased tool wear and eventually higher measured surface roughness values of
workpiece during machining. Thus, it is essential to study the effects of MQL machining with
Aluminium alloys.
Here, we have used Aluminium 6061 Alloy as our workpiece which consists of:
97.9% of Al, 0.6% of Si, 1.0% of Mg, 0.2% of Cr, 0.28% of Cu.
Machining of Aluminium (Al) alloys are most machinable of the common materials. The low
melting point of the material and the highest coefficients of expansion along with relative
softness and elasticity make it necessary to dissipate the generated heat. Otherwise, it is
difficult to maintain tolerances of the workpiece. Al alloys normally have significant amounts
of Si causing them to be adhesive, promoting rapid heat generation resulting in chip welding
and BUE(Built-up-Edge). Compared to the other materials, the machining of Al alloys is
much eases as it is a comparatively soft material, thus resulting in a longer Tool Life and
much reduced Cutting Fluid. But in addition to these properties, for a satisfactory outcome,
the other factors that also have to be fulfilled are the problems of material adhesion as well as
the BUE(Built-up-Edge) formation that shortens the Tool Life and causes other machining
problems. Thus, a properly optimized tool geometry as well as the machining parameters are
highly recommended for the machining of Al and its alloys in order to achieve proper results.

17
2. HSS (HIGH SPEED STEEL):
An alloy tool steel which when heat-treated retains much of its hardness and toughness at red
heat thus enabling tools made of it to cut at high speeds even though red-hot through friction.
It is commonly used as cutting tool material. It is superior to the older high-carbon steel tools
used extensively through the 1940s in that it can withstand higher temperatures without
losing its temper (hardness). This property allows HSS to cut faster than high carbon steel,
hence the name high-speed steel.
HSSs are heavily alloyed, ferrous, conventionally cast tool materials that can be divided into
four main categories: tungsten-, molybdenum-, molybdenum-cobalt-, and molybdenum-
vanadium based grades.
HSS composition features chromium (4%), tungsten (approx. 6%), molybdenum (up to 10%),
vanadium (around 2%), cobalt (up to 9%) and carbon (1%). The different grade types depend
on the varying levels of elements added.High-speed steels are used primarily for the
manufacture of cutting tools. HSS tools can resist vibrations, whatever the type of machine
tool, even if rigidity has been lost over time and regardless of workpiece clamping conditions.
It can prevent mechanical shocks at tooth level in milling operations and cope with varying
lubrication conditions which may result in thermal changes.
3.CASTOR OIL USED AS LUBRICANT:
Castor oil is a vegetable oil pressed from castor beans. It is a colourless to very pale yellow
liquid with a distinct taste and odour. Its boiling point is 313 °C (595 °F) and its density is
0.961 g/cm3. It includes a mixture of triglycerides in which approximately 90 percent of fatty
acid chains are ricinoleates. Oleate and linoleates are the other significant components.Its
derivatives are used in the manufacturing of soaps, lubricants, hydraulic and brake fluids,
paints, dyes, coatings, inks, cold resistant plastics, waxes and polishes, nylon,
pharmaceuticals and perfumes.
Castor oil is well known as a source of ricinoleic acid, a monounsaturated, 18-carbon fatty
acid. Average composition of castor seed oil: Ricinoleic acid 85–95%, Oleic acid 2–6%,
Linoleic acid 1–5%, α-Linolenic acid 0.5–1%, Stearic acid 0.5–1%, Palmitic acid 0.5–1%,
Dihydroxystearic acid 0.3–0.5%, Others 0.2–0.5%.

18
3.4. EXPRIMENTAL SETUP:
In this study, the MQL setup was designed to be cost effective, portable and able to function
well on both turning and milling machines. The MQL system had to be designed and
developed before the experiment could be carried out. The developed MQL setup is shown in
the Figure 3.1.
Fig. 3.2. Schematic view of MQL unit.
The main principle of this design is the usage of a spray gun or nozzle, which is able to
provide a fine mist of oil-air mixture easily.
The nozzle used in this study is the gravity feed spray gun. The advantage of using gravity
feed gun compared to a conventional spray gun is that less pressure is required for it to
operate.
The nozzle is connected to the compressor via a high pressure hose. A stand was designed to
support the spray gun. The spray gun is sandwiched between two steel plates, and is clamped
by tightening the bolts.
There are two methods of mixing air and lubricant in MQL method: 1. Mixing inside the
nozzle 2. Mixing outside the nozzle. In the first method, the lubricant and air is mixed just
before reaching the nozzle in a mixing chamber. The oil-mist is then supplied through the
nozzle at high pressure onto the cutting zone. The oil performs the lubricating function while
highly pressurized compressed air performs the cooling action. In the second method, the
mixing of oil and compressed air is done in a separate mixing chamber. The figure below
illustrates the MQL techniques.

19
Fig.3.3. MQL Technique
The MQL needs to be supply at high pressure and impinged at high speed through the nozzle
at the cutting zone. The thin but high velocity stream of MQL was projected from a nozzle
along the cutting edge of the insert, as indicated in a frame within Fig.3.1 , so that the coolant
reaches as close to the chip–tool and the work–tool interfaces as possible. The photographic
view of the experimental set-up is shown in Fig. 3.1. The MQL jet has been used mainly to
target the rake and flank surface and to protect the auxiliary flank to enable better
dimensional accuracy.

20
Fig.3.4. The photographic view of Mixing Chamber setup.

21
Fig.3.5. The photographic view of the experimental set-up.
The experiment was carried out by plain turning an Aluminium bar on a lathe at two different
depth of cuts and three different cutting speeds under dry, wet and MQL machining
environment. This was performed to study the effect of varying conditions on the
machinability characteristics of the workpiece in regards to tool wear, surface roughness. In
this study, a newly designed cost effective MQL setup was developed for the turning
operation. The effects of different process parameters (depth of cut and cutting speeds) and
cutting environments (Dry, Wet and MQL) on the tool wear, surface roughness and chip
formation in turning Aluminium alloy 6061 were investigated. . The encouraging results

22
include significant reduction in tool wear rate and surface roughness by MQL mainly through
reduction in the cutting zone temperature and favourable change in the chip–tool and work–
tool interaction. The minimization of cutting fluid also leads to economical benefits by way
of saving lubricant costs and work piece/tool/machine cleaning cycle time.
Table 3.2- Experimental conditions table
Experimental Conditions
Machine tool Lathe Machine , pathak industries
Work specimen Material Aluminium Alloy 6061
Diamete
r
25.7mm
Length 150 mm
Cutting Tool Material HSS (High Speed Steel)
Process parameters Cutting
Velocity
Vc
[in terms of
n]
(in rpm)
230 rpm,310 rpm and 500 rpm
Feed
Rate S0
(in
mm/sec)
0.19, 0.28, 0.38
Depth of
Cut
(in mm)
0.5
Environment Dry, Wet and MQL
MQL Air 5-8 bar

23
Supply pressure
Lubrica
nt
Castor Oil- 40 GRADE
3.5. EXPERIMENTAL INVESTIGATION:
 Experiments have been carried out by plain turning a 25.7mm diameter and 150mm
long rod of aluminium in a powerful and rigid lathe (pathak machine company) at
industrial speed-feed combination under dry, wet and minimum quantity lubrication
conditions.
Table 3.3 : Experimental Table -

24
EXPERIMENTAL CONDITION
ENVIRONMENT
CUTTING
VELOCITY VC
[in terms of N]
(in RPM)
FEED RATE S0
(in mm/sec)
DEPTH OF
CUT
(in mm)
DRY
230 0.19 0.5
310 0.28 0.5
500 0.38 0.5
FLOODED
230 0.19 0.5
310 0.28 0.5
500 0.38 0.5
MQL
230 0.19 0.5
310 0.28 0.5
500 0.38 0.5
3.6. INSTUMENTAL REVIEW :
3.6.1.Weighing machine
A weight machine is an exercise machine used for weight training that uses gravity as the
primary source of resistance and a combination of simple machines to convey that resistance
to the person using the machine. Each of the simple machines (pulley, lever, wheel, incline)
changes the mechanical advantage of the overall machine relative to the weight.

25
Fig 3.6.1 – Weighing machine
3.6.2.Vernier calliper
A vernier scale is visual aid to take an accurate measurement reading between
two graduation markings on a linear scale by using mechanical interpolation; thereby
increasing resolution and reducing measurement uncertainty by using vernier acuity to reduce
human estimation error.
Vernier is a subsidiary scale replacing a single measured-value pointer, and has for instance
ten divisions equal in distance to nine divisions on the main scale. The interpolated reading is
obtained by observing which of the vernier scale graduations is co-incident with a graduation
on the main scale, which is easier to perceive than visual estimation between two points.
Such an arrangement can go to a higher resolution by using a higher scale ratio, known as the
vernier constant. A vernier may be used on circular or straight scales where a simple linear
mechanism is adequate. Examples are callipers and micrometers to measure to
fine tolerances. The Vernier principle of interpolation is also used for electronic displacement
sensors such as absolute encoders to measure linear or rotational movement, as part of an
electronic measuring.
Fig 3.6.2 – Vernier calliper

26
3.6.3.Electronic Thermometer
Electronic thermometers are relatively easy to use and measure temperatures from 31.6°-
42.2° C in predictive mode and from 26.7°-42.2° C in continuous mode. It detect temperature
changes using a thermo resistive device in which the electrical resistance changes in response
to changes in temperature. This device may be a thermistor or a thermocouple and is
incorporated into the tip of a probe. Electronic thermometers display either a predicted
equilibrium temperature based on measurements taken over 15-30 seconds (in predictive
mode) or an actual equilibrium temperature that is generally achieved in a minute or less (in
continuous mode).
Fig 3.6.3– Electronic thermometer
3.6.4. Metal cutting device
Metal cutting machines are machine tools used to fabricate parts by the removal of material,
typically metal. Metal cutting is “the process of removing unwanted material in the form of
chips, from a block of metal, using cutting tool”. A person who specializes in machining is
called a machinist. A room, building or company where machining is done is called a
Machine Shop. The history of metal cutting started in Egypt where a rotating device called
bowstring was used to drill holes in stones.

27
Fig 3.6.4 – Metal cutter machine
3.6.5 Surface Roughness Tester
Instruments used for roughness measurements > Contact-type Surface Roughness/Profile
Measuring Instruments.
Contact-type Surface Roughness
With contact-type surface roughness instruments, a stylus tip makes direct contact with the
surface of a sample. The detector tip is equipped with a stylus tip, which traces the surface of
the sample and electrically detects the vertial motion of the stylus.
Non-contact surface roughness/profile measuring Instruments
A non-contact measuring instrument uses light in place of the stylus of used in a contact-type
measuring instrument. These instruments come in multiple types, such as confocal and white
light interference, and vary depending on the principle used. There are also a variety of
contact-type detectors that have been changed into non-contact instruments by replacing the
probe with optical sensors and microscopes.
A Profilometer is a highly specialised meteorological measurement device that is used for the
determination of the roughness of a surface. As a measurement instrument, the profilometer
is very precise as it is expected to have the capacity to identify and quantify very small-scale
surface features. The roughness of a surface is categorised in grades as per the ISO 4287
standard from “N12” to “N1” A profilometer is a measuring instrument used to measure a
surface's profile, in order to quantify its roughness. Critical dimensions as step, curvature,
flatness are computed from the surface topography.

28
Fig 3.6.5 Profilometer
3.6.6 Thermocouple
A Thermocouple is a sensor used to measure temperature. Thermocouples consist of two wire
legs made from different metals. The wires legs are welded together at one end, creating a
junction. This junction is where the temperature is measured. When the junction experiences
a change in temperature, a voltage is created. It is an electrical device consisting of two
dissimilar electrical conductors forming an electrical junction. A thermocouple produces a
temperature-dependent voltage as a result of See beck effect, and this voltage can be
interpreted to measure temperature. Thermocouples are widely used as temperature sensors.
Fig 3.6.6 Thermocouple

29
Chapter No.4
CHAPTER No.4
METHODOLOGY

30
Methodology
4.1. Introduction:
Turning is the most common method used in the industry during the manufacturing of the
product. The main objective of the manufacturing plant is to produce good satisfying
technology and technique, due to this MQL (Minimum quantity lubrication) machining has
caught the attention of the researchers and technicians in the area of machining as an
alternative to traditional fluid. This is necessary for the industry to develop such a technique
to sustain in the competition. In MQL, we use only 5-40ml per hour of lubricant for turning
operation. By using MQL technique we get better surface finishing and as we use less
lubricant for machining operation, it results in the cost reduction of the product.
4.2. 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 and 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. 3.1.
 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. 3, so that the coolant
reaches as close to the chip–tool and the work–tool interfaces as possible.
 The reference photographic view of the experimental set-up is shown in fig. 3.4 and
fig. 3.5. 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 but reliable tool–work thermocouple technique will
employed to measure the average cutting temperature during turning at different vs
combinations by the uncoated carbide insert under dry, wet and MQL conditions.

31
Chapter No.5
Result and Discussion
CHAPTER No.5
RESULT AND DISCUSSION

32
5.1 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.
 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 favorable influence on other machinability indices.
 The experimental observed data was presented in graphical form.
Fig.5.1 A graphical representation between cutting temperature & cutting velocity in
three different condition.
5.2 EFFECT ON TOOL WEAR :

33
▪ During machining, 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.
▪ 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.
▪ Another important tool wear criteria is average 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 reduced which is expected to provide better surface finish.
▪ 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.
Table 5.1 : Tool wear condition show in this table
5.3 EFFECT ON SURFACE ROUGHNESS :
Dry Condition Flooded Condition MQL Condition
Initial wt. of tool=69.70g Initial wt. of tool=69.41g Initial wt. of tool=69.37g
Final wt. of tool=69.41g Final wt. of tool=69.37g Final wt. of tool=69.34g

34
▪ 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.
Fig.5.2. Surface Roughness
 In MQL condition tool/flank wear on auxiliary cutting edge is reduced, so surface
roughness is expected to increase under MQL condition.
 The major cause behind development of surface roughness is 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 sys1tem.
iv. Built-up-edge formation.

35
(a) (b)
Fig 5.3.(a),(b) -Final machined work piece

37
Chapter No.6
Conclusion
6.1 Conclusion
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 machining 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.

38
6.2. Future Scope:
The future may include the exploration of the effects of flow rates of coolant for the specific
tool material and subsequent effect on the machining performance. It would be interesting to
conduct a comparative study of use of different coolants and their effects on the machining
performance of specific material. Exploration of cutting forces measurement with use of
MQL and other cooling conditions like-Dry and Flood cooling can also be taken up to
provide insight for practitioners in selecting a proper coolant and lubrication system.
▪ Here, water miscible cutting fluid and Mineral-oil based cutting fluid can be used.
Water miscible cutting fluids are those cutting fluids which contain water as the main
base fluid. Water is a fluid which has got excellent cooling property. This cutting
fluids have good heat absorbing characteristics.
▪ In case of Mineral-oil based cutting fluid, oils do not get mixed with water. They can
be used as mixtures of mineral or vegetable oils. Several additive compounds such as
Sulphur, Phosphorous, Chlorine based components can be added to the base cutting
fluids in order to improve their cooling and lubricating properties.
▪ Also the MQL Setup can be automised by using different software so that any small
rise in temperature between the work-tool interface will activate the MQL setup for
cooling as well as lubricating between the work-tool interface.
▪ Introduction of nano particles in lubrication process and new development of MQL
technology using nano-fluids 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 assessment 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.

39
REFERENCES
[1] N.R. Dhar ,M. Amruzzaman, Mahiuddin Ahmed, Cutting performance of MQL
machining is better than that of dry and conventional machining with flood cutting
fluid supply.
[2] B. Tasdelena, T. Wikblomb, S. Ekeredc, Highest wear both for center and periphery
inserts was observed using emulsion, followed by air and MQL assisted machining.
[3] Brian Boswell, Mohammad Nazrul Islam, “Feasibility Study of Adopting Minimal
Quantities of Lubrication for End Milling Aluminium Proceedings of the World
Congress on Engineering”
[4] Ahmadreza Hosseini Tazehkandi, Mohammadreza Shabgard, Farid Pilehvarian,
“Application of liquid nitrogen and spray mode of biodegradable vegetable cutting
fluid with compressed air in order to reduce cutting fluid consumption in turning
Inconel 740” Journal of Cleaner Production
[5] Radoslaw W. Maruda, Grzegorz M. Krolczyk, Eugene Feldshtein, Piotr Nieslony,
Bozena Tyliszczak, Franci Pusavec, (2016)“Tool wear characterizations in finish
turning of AISI 1045 carbon steel for MQCL conditions.
[6] Tim Walker, The MQL Handbook, A guide to machining with minimum quantity
lubrication Units.
[7] N.R.Dhar, M.W.islam,S.Islam,M.A.H.Mithu,“The influence of MQL on cutting
temperature, chip and dimensional accuracy in turning AISI- 1040steel” journal of
material processing technology
[8] D.M. D'Addona, Sunil J Raykar , “Analysis of surface roughness in hard turning using
wiper insert geometry” 48th CIRP Conference on manufacturing systems – CIRP.
[9] C. Cassin, G. Boothroyd, Lubrication action of cutting fluids, J. Mech. Eng. Sci. 7 (1)
(1965) 67–81.
[10] M. Mazurkiewicz, Z. Kubala, J. Chow, Metal machining with high pressure water-jet
cooling assistance—a new possibility, J. Eng. Ind. 111 (1989) 7–12.
[11] Hasan MF, Dwivedi A, ”Study and analysis of natural oil based cutting fluids using
MQL system for alloy steel”

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