An investigation on the performance of nanoparticle enriched cutting fluid in machining of aisi 304 steel

Abstract

In every conventional machining process, interaction of tool interface with the workpiece results in high temperatures and thermal distortions. Such distortions may lead to change in the surface morphology of the machined workpiece, thus harming the desired finishing of the product. The use of nanofluids as a coolant over traditional cutting fluid helps in minimizing such problems. In continuation to the past research on nanofluids, the use of hybrid nanofluids in machining operations is attracting the researchers. The synthesis of hybrid nanofluids is done by dispersing two different nanoparticles in traditional heat transfer fluid which can be seen as efficient coolant and lubricant. The hybrid nanofluids are found favorable in terms of thermo physical properties, heat transfer rate and stability. This has led to increase in research on hybrid nanofluids over mono type nanofluids. newlineIn this work, alumina (Al2O3) nanoparticles of three different average particle sizes 30 nm, 40 nm and 50 nm are used for enriching the cutting fluid used for machining. The nanofluids developed are used in 3 different vol. concentrations of 0.5%, 1% and 1.5 % respectively. To investigate the tribological performance and spreadability (contact angle) of nanofluids, each sample is tested using pin on disk tribometer and goniometer respectively. Further to assess the performance as a cooling, turning operation on AISI 304 steel is performed with these developed nanofluids under mist lubrication environment. For the purpose of experimentation, four input parameters namely cutting speed, depth of cut, nanoparticle concentration and feed rate are used for analyzing the cutting forces. The design of experiment (DOE) and regression models are developed using Response surface methodology (RSM). The confirmatory experiment performed revealed an error of 5.7%, 8.8% and 7.8% respectively in case of 30 nm, 40 nm and 50 nm average particle size of alumina. newlineThereafter, in this work multiple responses, namely, force, surface roughness, and temperature