A Comparative Machinability Study of SS 304 in Turning under Dry, New Micro-Jet, and Flood Cooling Lubrication Conditions
, Hillol Joardar 2, Borhen Louhichi 1, Naser Abdulrahman Alsaleh 1 and Adel Alfozan 1
Round 1
Reviewer 1 Report
Dear Authors
I appreciate your work on introducing the concept of Microjet. You have also carried out substantial number of applications but I feel the manuscript must have scientific reasoning behind your presentations. Few are my comments:
i. The nano-particles mixed in the mist can easily be entered into the operator "lungs where a rapid translocation through the blood stream is possible to other vital organs. : Most of the industrial high speed machining are in closed enclosure so this line is somewhat misleading. Please include few references where it has been observed that operators have health issues.
ii. The authors have presented the concept of "Micro jet" but not substantial details have been given on this technology. Since, it is a novel concept the authors must represent the design and present more details of the micro jet.
iii.Figure 9: the cutting tool of what?
iv. In flooding we have advanantages of better chip and less oxidized chips. Doesn't it indicates that the micro jet is not a good choice? However, you have mentioned that tool life and MRR is good.. These two observations are little conflicting.
v. The scientific reasons are still missing. The manuscript seems to be like more of detailed experimental report. Please focus on the scientific reasons why oxidation was more in micro jet, why chip was less in length in micro jet , why MRR was better in micro jet etc.
vi. What about the workpiece surface characterization? Any surface damages or stressed areas on the workpiece?
I feel that at present the manuscript is not fully ready with scientific reasons. Also, more details of the micro jet design should be provided as the authors are focusing on micro jet usage. Authors also need to provide the physics behind the micro jets.
Author Response
- The nano-particles mixed in the mist can easily be entered into the operator "lungs where a rapid translocation through the blood stream is possible to other vital organs.: Most of the industrial high speed machining are in closed enclosure so this line is somewhat misleading. Please include few references where it has been observed that operators have health issues.
Answer: The section is rewritten. The mentioned statement is taken from reference no [22] without change" ….".
- The authors have presented the concept of "Micro-jet" but not substantial details have been given on this technology. Since, it is a novel concept the authors must represent the design and present more details of the micro-jet.
Answer: The schematic view of the micro-jet set-up (pneumatic) circuit diagram and micro-jet supply mechanism are given in Figures 5 (a) and (b) respectively. We are presently working on high-pressure applications of micro-jet in the finishing cycle (high speed, low feed rare, and low depth of cut). We will explore the detailed updated design of micro-jet MQL system in the next publication.
iii.Figure 9: the cutting tool of what?
Answer: Yes. updated
- In flooding we have advanantages of better chip and less oxidized chips. Doesn't it indicates that the micro jet is not a good choice? However, you have mentioned that tool life and MRR is good.. These two observations are little conflicting.
Answer: In this present study, it is observed that flood cooling condition is favourable for metal removal but not good for cutting tool health (due to predominant BUE, edge chipping and edge breaking occurrence). MQL machining condition is observed as an optimum environment by considering MRR and tool health (shown in Figure 18 ).
- The scientific reasons are still missing. The manuscript seems to be like more of detailed experimental report. Please focus on the scientific reasons why oxidation was more in micro jet, why chip was less in length in micro jet , why MRR was better in micro jet etc.
Answer: (i) More scientific explanations are added to explain the machining chip formation and cutting tool performance. (ii) MRR was observed as intermediate in MQL than the other two conditions. It might be due to a significant improvement in reducing friction in MQL than dry machining.
- What about the workpiece surface characterization? Any surface damages or stressed areas on the workpiece?
Answer: This present work is done on bulk MRR. The authors felt that surface finishing is done in the finishing cycle at high cutting speed, low feed rate, and low depth of cut combination after bulk MRR. In our next part investigation, we have considered surface characterizations( like roughness, surface damage, etc.) as a part of major responses.
Author Response File: 
Author Response.pdf
Reviewer 2 Report
1. Remove all typos and grammatical mistakes see lines 42, 45, 46, 98, 113, Table 4 (chip ovservations), lines 341, 342, 425, 434, and many more places.
2. The authors need to put more details regarding the flood and existing MQL techniques with all the advantages and disadvantages.
3. Can authors replace the high-speed machining term with the high-performance machining term as most of the researchers are using it for HPM.
4. The literature review needs updations as in the current version only one paper from 2022 is included. There are numerous papers published in the year 2022, Please include it.
5. Line 76 Need more details “alarming health issues related to nano-solid lubricants”
6. Remove discontinuity with all sections and sub-sections.
7. Can the authors explain how much power is high in dry machining and what causes the power to be high?
8. No need for this sentence “The analytical study reduces practical efforts and may avoid the need for costly measuring instruments and equipment.” As the authors are not using it in their current work.
9. No details regarding the velocity of the jet, flow rate, power consumption of the machine, pressure and temperature of the lubricant is provided in the current version.
10. Figure 4 is good for thesis only; I will suggest the authors explain the novelty in one paragraph and present it in a more concise way. Explain the novel features of your design.
11. Add a table showing the % error of experimental findings vs Modelling Results instead of Figure 16.
12. Figure 18 Resolution is very poor.
13. Table 12 needs a scale
14. What is the justification of shorter chips in dry and longer chips in flood cooling?
15. But oxidation will be dominant in flood cooling as compared to dry and MQL, what is the reason for color change?
16. The authors did not mention the two essential parameters of Machining i.e cutting forces and surface quality. Surface quality is especially important for the reader, How much improvement can be achieved with the current setup compared to the existing setup?
17. What are the novel features of your design compared to the existing and published design available in the literature?
Author Response
- Remove all typos and grammatical mistakes see lines 42, 45, 46, 98, 113, Table 4 (chip ovservations), lines 341, 342, 425, 434, and many more places.
Answer: Done
- The authors need to put more details regarding the flood and existing MQL techniques with all the advantages and disadvantages.
Answer: Added
- Can authors replace the high-speed machining term with the high-performance machining term as most of the researchers are using it for HPM.
Answer: The term "high-speed machining" is a general term used in textbook [ref. 1]. Our target is to achieve "high-performance machining" after doing a detailed experiment. We will use this term in our next part of the investigation where we are expecting to get better performance by using high-pressure micro-jet in higher-speeds in machining SS 304.
- The literature review needs updations as in the current version only one paper from 2022 is included. There are numerous papers published in the year 2022, Please include it.
Answer: Added
- Line 76 Need more details “alarming health issues related to nano-solid lubricants”
Answer: Added
- Remove discontinuity with all sections and sub-sections.
Answer: Done
- Can the authors explain how much power is high in dry machining and what causes the power to be high?
Answer: Power consumption is higher in dry machining due to relatively more friction in the cutting tool-workpiece interface as compared other processes.
- No need for this sentence “The analytical study reduces practical efforts and may avoid the need for costly measuring instruments and equipment.” As the authors are not using it in their current work.
Answer: The sentence is removed
- No details regarding the velocity of the jet, flow rate, power consumption of the machine, pressure and temperature of the lubricant is provided in the current version.
Answer: Added as per the reviewer's advice and the details are given as per scopes
- Figure 4 is good for thesis only; I will suggest the authors explain the novelty in one paragraph and present it in a more concise way. Explain the novel features of your design.
Answer: Figure 4 is removed. The novelty of the work is added in the Graphical abstract. The novel features of the design are added.
- Add a table showing the % error of experimental findings vs Modelling Results instead of Figure 16.
Answer: Done
- Figure 18 Resolution is very poor.
Answer: Updated
- Table 12 needs a scale
Answer: Updated
- What is the justification of shorter chips in dry and longer chips in flood cooling?
Answer: Justification is added
- But oxidation will be dominant in flood cooling as compared to dry and MQL, what is the reason for color change?
Answer: Justification is added
- The authors did not mention the two essential parameters of Machining i.e cutting forces and surface quality. Surface quality is especially important for the reader, How much improvement can be achieved with the current setup compared to the existing setup?
Answer: This present work is done on bulk MRR. The authors felt that surface finishing is done in the finishing cycle at high cutting speed, low feed rate, and low depth of cut combination after bulk MRR. In our next part investigation, we have considered surface characterizations( like roughness, surface damage, etc.) as a part of major responses.
One objective of this work is to investigate machinability with a cost-effective budget. The piezo-electic dynamometer is needed for precise measurement of cutting forces and the instrument is costly. It may be out of reach to purchase such costly instruments by general/small machining industries. The chip (reduction coefficient, colour, types ) study is the classical way to understand machining comfort zone which is tried here for general-purpose use. (We will do force measurement in the next part of the investigation as mentioned earlier)
- What are the novel features of your design compared to the existing and published design available in the literature?
Answer: Some researchers mentioned working with mist MQL, atomizer MQL, drop-by-drop MQL etc. process but as per the search and review of the present authors, the micro-jet approach is not reported. The set-up design and mechanism details are added.
Author Response File: Author Response.pdf
Reviewer 3 Report
The authors presented an article about “A comparative machinability study of SS304 in turning under dry, new micro-jet and flood cooling lubrication”. It is possible to say that the article has a subject that can attract the attention of the readers. In addition, I believe that the C/L conditions mentioned in the article can contribute to the dissemination of industrial use. The author has successfully constructed the article. I think it is particularly interesting to use different experimental design systems and support them with ANN. In general, it is possible to say that the authors were successful. I think the paper is well organized and is appropriate for “Lubricants” journal but the paper will be ready for publication after major revision.
· The abstract looks good. Please include significance results
· For the introduction section, please add more reference and briefly explain them.
· In the last paragraph of the introduction, it should be expressed the novelty of the study, the differences from the past in detail.
· How were the chemical properties of the material determined? (Table 3)
· Explain the features of cutting tool geometry with figure.
· Which liquid was used for the flood environment and how was it prepared?
· The resolution of the figures and tables should be increased (Particularly Fig. 17-18).
· Please check and correct your citation style in the article (For example in line 72: Hamran et al. [7], …..).
· Please write the expansion of the abbreviations where they are first used (BUE, MQL, MPQ).
· Please correct the reference form in Table 1. [1, 11-13].
· The title of the article must be in accordance with the content of the article. Please change the article title to cover all C/L conditions.
· Are there copyright permissions for the figure?
· Improve the conclusion parts.
· Please review journal writing guidelines. You should pay particular attention to line spacing (For example; page 13/24). Also Please fix the typographical and eventual language problems in paper.
· The paper is well-organized yet there is a reference problem. First, your reference list contains no paper from “Lubricants” journal. If your work is convenient for this journal’s context then there are many references from this journal. Secondly, cited sources should be primary ones. Namely, indexed area shows the power of a paper and directly your paper’s reliability. Please make regulations in this direction.
· For the introduction, please add more current references and briefly explain them. For this, you can use the following literature related to the article.
https://doi.org/10.3390/lubricants10110301
https://doi.org/10.1016/j.jmrt.2022.09.067
https://doi.org/10.1016/j.triboint.2022.107677
*** Authors must consider them properly before submitting the revised manuscript. A point-by-point reply is required when the revised files are submitted.
Author Response
Comments and Suggestions for Authors
The authors presented an article about “A comparative machinability study of SS304 in turning under dry, new micro-jet and flood cooling lubrication”. It is possible to say that the article has a subject that can attract the attention of the readers. In addition, I believe that the C/L conditions mentioned in the article can contribute to the dissemination of industrial use. The author has successfully constructed the article. I think it is particularly interesting to use different experimental design systems and support them with ANN. In general, it is possible to say that the authors were successful. I think the paper is well organized and is appropriate for “Lubricants” journal but the paper will be ready for publication after major revision.
- The abstract looks good. Please include significance results
Answer: added
- For the introduction section, please add more reference and briefly explain them.
Answer: added
- In the last paragraph of the introduction, it should be expressed the novelty of the study, the differences from the past in detail.
Answer: We have mentioned the novelty of the work in the Graphical abstract
- How were the chemical properties of the material determined? (Table 3)
Answer: Taken from the data sheet provided by the material supplier.
Explain the features of cutting tool geometry with figure.
Answer: Done
- Which liquid was used for the flood environment and how was it prepared?
Answer: mentioned
- The resolution of the figures and tables should be increased (Particularly Fig. 17-18).
Answer: Done
- Please check and correct your citation style in the article (For example in line 72: Hamran et al. [7], …..).
Answer: Done
- Please write the expansion of the abbreviations where they are first used (BUE, MQL, MPQ).
Answer: The nomenclature list is added at the end
- Please correct the reference form in Table 1. [1, 11-13].
Answer: Done
- The title of the article must be in accordance with the content of the article. Please change the article title to cover all C/L conditions.
Answer: Done
- Are there copyright permissions for the figure?
Answer: The figures have no copy write issue
- Improve the conclusion parts.
Answer: Done
- Please review journal writing guidelines. You should pay particular attention to line spacing (For example; page 13/24). Also Please fix the typographical and eventual language problems in paper.
Answer: Updated
- The paper is well-organized yet there is a reference problem. First, your reference list contains no paper from “Lubricants” journal. If your work is convenient for this journal’s context then there are many references from this journal. Secondly, cited sources should be primary ones. Namely, indexed area shows the power of a paper and directly your paper’s reliability. Please make regulations in this direction.
Answer: Updated as suggested
- For the introduction, please add more current references and briefly explain them. For this, you can use the following literature related to the article.
https://doi.org/10.3390/lubricants10110301
https://doi.org/10.1016/j.jmrt.2022.09.067
https://doi.org/10.1016/j.triboint.2022.107677
*** Authors must consider them properly before submitting the revised manuscript.
Answer: Yes, referred (more papers).
A point-by-point reply is required when the revised files are submitted.
Answer: Tried to meet
Author Response File: Author Response.pdf
Round 2
Reviewer 1 Report
The manuscript has been improved and can be accepted for publication following journal's review process.
Reviewer 2 Report
Dear Authors, Thanks a lot for incorporating all changes and explaining the limitation that you have faced in your work. However, the paper is improved.
Reviewer 3 Report
Thanks to the authors for the revisions.
