Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication
Also available in printed version
| 第一著者: | |
|---|---|
| その他の著者: | |
| フォーマット: | Doctoral thesis |
| 言語: | 英語 |
| 出版事項: |
Universiti Teknologi Malaysia
2025
|
| 主題: | |
| オンライン･アクセス: | https://utmik.utm.my/handle/123456789/51793 |
| Abstract | Abstract here |
| _version_ | 1854975122125881344 |
|---|---|
| author | Elmunafi, Mohamed Handawi Saad |
| author2 | Noordin Mohd. Yusof, supervisor |
| author_facet | Noordin Mohd. Yusof, supervisor Elmunafi, Mohamed Handawi Saad |
| author_sort | Elmunafi, Mohamed Handawi Saad |
| description | Also available in printed version |
| format | Doctoral thesis |
| id | utm-123456789-51793 |
| institution | Universiti Teknologi Malaysia |
| language | English |
| publishDate | 2025 |
| publisher | Universiti Teknologi Malaysia |
| record_format | dspace |
| record_pdf | Abstract |
| spelling | utm-123456789-517932025-08-21T14:35:30Z Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication Elmunafi, Mohamed Handawi Saad Noordin Mohd. Yusof, supervisor Mechanical engineering Also available in printed version Cutting fluids have been used successfully in machining to suppress tool wear, enhance surface quality, and reduce cutting forces and temperature. However, cutting fluids have negative effects on the cost of handling and to the environment. This study was undertaken to evaluate the performance of PVD TiAlN coated carbide cutting tools (KC5010) when turning martensitic stainless steel (AISI 420) with hardness 48±1 HRC under dry and Minimum Quantity Lubrication (MQL) conditions. The depth of cut was kept constant at 0.2 mm. For MQL, two (2) different cutting fluids were used viz. castor oil and mixture of castor oil and iron oxide (?-Fe2O3) nanoparticles. The evaluation was in terms of tool life, surface roughness and cutting forces. Wear mechanism and chip morphology were also investigated. The cutting conditions investigated were low, medium and high combinations of cutting speed (100, 135 and 170 m/min) and feed rate (0.16, 0.20 and 0.24 mm/rev). Under MQL, the flow rate of lubricant and air pressure were 50 ml/h and 5 bar, respectively. In the first stage, 2 different techniques of cutting, viz dry cutting and MQL, were compared at low, medium and high cutting parameters. Based on the result of stage 1, further experiments were performed in stage 2 to completely investigate the effects of cutting speed and feed rate on the responses. MQL using castor oil containing different quantities of ?-Fe2O3 nanoparticles (0.4%, 0.8%, and 1.2% by weight) were explored in stage 3. MQL using castor oil as cutting fluid produced better results when compared to dry cutting in terms of longer tool life. Surface roughness and cutting forces were also enhanced albeit slightly. MQL using castor oil was used for the remaining experiments of 32 factorial design with two (2) center points. The results showed that cutting speed and feed rate are significant factors. The longest tool life, better surface roughness and lower cutting forces were obtained at low cutting speed and feed rate. However, the highest material removal rate was obtained at low cutting speed and medium feed rate. Crater and flank wear were the dominant tool wear at low and medium cutting speeds and feed rates for dry and MQL conditions. Adhesion wear was found to be the wear mechanism when turning hardened stainless steel under dry and MQL conditions. Continuous chips were observed at low speed and saw tooth chip at high speed for dry and MQL conditions. The tool life, surface roughness and cutting forces empirical models were developed. The models can be used to predict the machining responses within the limits of cutting speed and feed rate that have been investigated. MQL using castor oil containing 1.2% wt of ?-Fe2O3 nanoparticles performed best in terms of tool life, surface roughness and cutting forces compared to dry hard turning and MQL castor oil. The best performance was achieved at 100 m/min and 0.16 mm/rev where the tool life improvement were 142% and 27% compared to dry and MQL castor oil respectively, surface roughness were enhanced by 22% and 16% compared to dry and MQL castor oil conditions respectively and cutting forces were reduced by 22% and 17% compared to dry and MQL castor oil conditions respectively fahmimoksen UTM 277 p. Thesis (Ph.D (Kejuruteraan Mekanikal)) - Universiti Teknologi Malaysia, 2016 2025-03-14T06:33:26Z 2025-03-14T06:33:26Z 2016 Doctoral thesis https://utmik.utm.my/handle/123456789/51793 vital:106526 valet-20180103-161427 ENG Closed Access UTM Complete Unpublished Completion application/pdf Universiti Teknologi Malaysia |
| spellingShingle | Mechanical engineering Elmunafi, Mohamed Handawi Saad Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication |
| thesis_level | PhD |
| title | Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication |
| title_full | Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication |
| title_fullStr | Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication |
| title_full_unstemmed | Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication |
| title_short | Performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication |
| title_sort | performance evaluation of finish hard turning using coated carbide cutting tools under minimum quantity lubrication |
| topic | Mechanical engineering |
| url | https://utmik.utm.my/handle/123456789/51793 |
| work_keys_str_mv | AT elmunafimohamedhandawisaad performanceevaluationoffinishhardturningusingcoatedcarbidecuttingtoolsunderminimumquantitylubrication |