Evaluation of nano fluids in minimum quantity lubrication hard machining of Monel K500 material for high heat-resistant application

ABSTRACT

In turning, the interaction among target material tool and chip usually causes thermal damage as well as tool wear. High-pressure coolant is an emerging technology that delivers and the tool interface region. High coolant pressure allows better penetration of coolant by enhancing the lubrication effect, and decreasing thermal damage and tool wear through cooling effect at the cutting zone. The manufacturing sector wants to create a lot of goods in a short amount of time as the fourth industrial revolution approaches. Response surface design and the Taguchi L27 orthogonal array methodological paradigm are used in this work. The cutting speed (750, 1000, 1250 rpm), feed rate (0.075, 0.1, 0.125 mm/rev), depth of cut (0.25, 0.50, 0.75 mm), and fluid pressure (2.5, 5, 7.5 bar) represent as the process parameters. The objective of this paper, is to investigate how the surface finish, cutting force, and tool wear mechanism are influenced by coolants under the different coolant pressure, depth of cut, feed and speed in turning of monel using coated carbide tool. Also in this work the performance of cutting coolant (CuO and graphene) were compared with respect to tool wear, cutting force, surface roughness, cutting zone temperature chip morphology and surface modification during turning of monel. The findings showed that, under extreme wear conditions, GO-based nano fluids improved machining performance, as measured by increased cooling and lubrication regime, cutting temperature of 122 °C, and surface roughness of 0.0462 µm and flank wear of 0.2 mm.

Keywords:
Machining; Monel K500 Alloy; Nanofluids; Surface Roughness; Tool Wear