The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel
Abstract
:1. Introduction
2. Methodology
2.1. Cutting Tool, Workpiece and Machine Tool Conditions
2.2. Experiments and Cutting Environments
2.3. Measurement of Tool Wear, Cutting Temperature, and Consumed Power
2.4. Experimental Design, Optimization Approach, and Statistical Analysis
3. Results and Discussion
3.1. Evaluation of Flank Wear under MQL and Dry Cutting Conditions
3.2. Evaluation of Cutting Temperature under MQL and Dry Cutting Conditions
3.3. Evaluation of Power Consumption under MQL and Dry Cutting Conditions
3.4. ANOVA Results for the Wear Rate, Weight Loss, and Coefficient of Friction
3.5. Optimization of Response Parameters under MQL and Dry Cutting Conditions
4. Conclusions
- A comparison of MQL and dry environments was carried regarding tool wear, cutting temperatures, and power consumption. MQL results in vital performance improvements in the milling of AISI 1040 steel, due to its ability to remove chips and to cool and lubricate the cutting area. The tool wear progressions clearly showed that MQL-assisted milling provided better flank wear results than dry cutting under the same cutting conditions. For higher cutting speeds especially (150 m/min), the differences were much greater than for lower cutting speeds (10 m/min);
- When MQL and dry environments were compared in terms of flank wear, peak temperature, and power consumption, improvements of 30.9%, 32.5%, and 16.9% achieved, respectively;
- The main benefit of the application of MQL is due to the oil droplets being transmitted to the cutting area during milling operation, reducing the cutting forces by improving the cutting ability of the cutting tool and directly decreasing the power consumption. Better cutting ability brings about resistance to wear, meaning a longer tool life can be achieved. The same mechanism allows for lower cutting temperatures due to the better tribological properties provided by MQL;
- Thanks to the better cooling and lubrication properties of MQL, the best flank wear, cutting temperature, and power consumption results were obtained under MQL conditions, along with lower cutting speeds (100 m/min). Regarding the minimum cutting temperature, a high feed rate (0.15 mm/rev) and cutting speed (150 m/min) and MQL-assisted milling should be selected;
- The ANOVA tables outlined the efficacy of the parameters used. Accordingly, the cutting environment is the most effective factor in terms of reducing power consumption (37%) and cutting temperatures (94.5%). On the other hand, flank wear is affected most by cutting speed (74%).
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Fe | Mn | C | S | P |
bal. | 0.9 | 0.44 | 0.05 | 0.04 |
Signature | Parameters | Unit | Level 1 | Level 2 |
---|---|---|---|---|
vC | Cutting Speed | m/min | 100 | 150 |
f | Feed Rate | mm/rev | 0.1 | 0.15 |
e | Environment | - | DRY | MQL |
Experiment Number | Factor A Environment (mL/h) | Factor B Cutting Speed (m/min) | Factor C Feed Rate (mm/rev) |
---|---|---|---|
1 | 1 | 1 | 1 |
2 | 1 | 1 | 2 |
3 | 1 | 2 | 1 |
4 | 1 | 2 | 2 |
5 | 2 | 1 | 1 |
6 | 2 | 1 | 2 |
7 | 2 | 2 | 1 |
8 | 2 | 2 | 2 |
Experiment Number | Environment | Cutting Speed (m/min) | Feed Rate (mm/rev) | Flank Wear (mm) | Cutting Temperature (°C) | Consumed Power (J/s) |
---|---|---|---|---|---|---|
1 | DRY | 100 | 0.1 | 0.344 | 130.4 | 76.3 |
2 | DRY | 100 | 0.15 | 0.405 | 137.9 | 89 |
3 | DRY | 150 | 0.1 | 0.656 | 143.4 | 79.5 |
4 | DRY | 150 | 0.15 | 0.659 | 124.7 | 81 |
5 | MQL | 100 | 0.1 | 0.325 | 96.4 | 74.8 |
6 | MQL | 100 | 0.15 | 0.381 | 88 | 73.9 |
7 | MQL | 150 | 0.1 | 0.453 | 90.3 | 78.02 |
8 | MQL | 150 | 0.15 | 0.509 | 94.3 | 77.8 |
Source | DOF | SS | MS | F Value | p-Value | PC (%) |
---|---|---|---|---|---|---|
Flank Wear | ||||||
Cutting Speed | 1 | 29.0157 | 29.0157 | 227.62 | 0.042 | 74 |
Feed Rate | 1 | 1.8536 | 1.8536 | 14.54 | 0.163 | 4.8 |
Environment | 1 | 5.2546 | 5.2546 | 41.22 | 0.098 | 13.4 |
Cutting Speed × Feed Rate | 1 | 0.3814 | 0.3814 | 2.99 | 0.334 | 1 |
Cutting Speed × Environment | 1 | 2.4591 | 2.4591 | 19.29 | 0.143 | 6.3 |
Feed Rate × Environment | 1 | 0.1094 | 0.1094 | 0.86 | 0.524 | 0.2 |
Error | 1 | 0.1275 | 0.1275 | - | - | 0.3 |
Total | 7 | 39.20 | - | - | - | 100 |
Cutting Temperature | ||||||
Cutting Speed | 1 | 0.000 | 0.00 | 0.00 | 0.997 | 0 |
Feed Rate | 1 | 0.1634 | 0.1634 | 0.16 | 0.758 | 0.8 |
Environment | 1 | 21.0275 | 21.0275 | 20.45 | 0.139 | 94.5 |
Cutting Speed × Feed Rate | 1 | 0.0352 | 0.0352 | 0.03 | 0.883 | 0.1 |
Cutting Speed × Environment | 1 | 0.0008 | 0.0008 | 0.00 | 0.982 | 0 |
Feed Rate × Environment | 1 | 0.0122 | 0.0122 | 0.01 | 0.931 | 0.1 |
Error | 1 | 1.0280 | 1.0280 | - | - | 4.5 |
Total | 7 | 22.2672 | - | - | - | 100 |
Power Consumption | ||||||
Cutting Speed | 1 | 0.01545 | 0.01545 | 0.08 | 0.826 | 0.8 |
Feed Rate | 1 | 0.23461 | 0.23461 | 1.19 | 0.472 | 13 |
Environment | 1 | 0.66165 | 0.66165 | 3.36 | 0.318 | 37 |
Cutting Speed × Feed Rate | 1 | 0.14970 | 0.14970 | 0.76 | 0.544 | 8.3 |
Cutting Speed × Environment | 1 | 0.20290 | 0.20290 | 1.03 | 0.495 | 11.3 |
Feed Rate × Environment | 1 | 0.33184 | 0.33184 | 1.68 | 0.418 | 18.6 |
Error | 1 | 0.19706 | 0.19706 | - | - | 11 |
Total | 7 | 1.79320 | - | - | - | 100 |
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Salur, E.; Kuntoğlu, M.; Aslan, A.; Pimenov, D.Y. The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel. Metals 2021, 11, 1674. https://doi.org/10.3390/met11111674
Salur E, Kuntoğlu M, Aslan A, Pimenov DY. The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel. Metals. 2021; 11(11):1674. https://doi.org/10.3390/met11111674
Chicago/Turabian StyleSalur, Emin, Mustafa Kuntoğlu, Abdullah Aslan, and Danil Yurievich Pimenov. 2021. "The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel" Metals 11, no. 11: 1674. https://doi.org/10.3390/met11111674