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COMPREHENSIVE MATERIALSFINISHING
EDITOR-IN-CHIEF
MSJHASHMI
DublinCityUniversity,Dublin,Ireland
VOLUME1
FINISHMACHININGANDNET-SHAPEFORMING
VOLUMEEDITOR IMTIAZACHOUDHURY
UniversityofMalaya,KualaLumpur,Malaysia
CONTRIBUTORSTOVOLUME1
AAAbdullahi
UniversityofMalaya,KualaLumpur,Malaysiaand FederalUniversityofTechnology,Minna,Nigeria
MYAli
InternationalIslamicUniversityMalaysia,Kuala Lumpur,Malaysia
SNAAziz UniversityofMalaya,KualaLumpur,Malaysia
MAzuddin UniversityofMalaya,KualaLumpur,Malaysia
RBahar
InternationalIslamicUniversityMalaysia,Kuala Lumpur,Malaysia
KCBala
FederalUniversityofTechnology,Minna,Nigeria
SKChaubey
IndianInstituteofTechnologyIndore,Indore,India
SChinchanikar
VishwakarmaInstituteofInformationTechnology,Pune, India
IAChoudhury UniversityofMalaya,KualaLumpur,Malaysia
SKChoudhury
IndianInstituteofTechnologyKanpur,Kanpur,India
YAEl-Shekeil
UniversitiPutraMalaysia,Serdang,Malaysia
FengfengJeffXi
RyersonUniversity,Toronto,ON,Canadaand ShanghaiUniversity,Shanghai,P.R.China
SGencalpIrizalp
CelalBayarUniversity,Manisa,Turkey
MHourmand UniversityofMalaya,KualaLumpur,Malaysia
HuiYe
XiamenUniversity,Xiamen,China
WNPHung
TexasA&MUniversity,CollegeStation,TX,USA
MSAHussin
UniversityofMalaya,KualaLumpur,Malaysia
NKJain
IndianInstituteofTechnologyIndore,Indore,India
JianWang
FineOpticalEngineeringResearchCenter,Chengdu, China
SALawal
FederalUniversityofTechnology,Minna,Nigeria SSLawal FederalUniversityofTechnology,Minna,Nigeria
IMaher
UniversityofMalaya,KualaLumpur,Malaysia andKafrelsheikhUniversity,Kafrelsheikh, Egypt
HMarashi UniversityofMalaya,KualaLumpur,Malaysia NNahar UniversityofMalaya,KualaLumpur,Malaysia
MBNdaliman FederalUniversityofTechnology,Minna,Nigeria MYNoordin UniversitiTeknologiMalaysia,JohorBahru,Malaysia YNukman UniversityofMalaya,KualaLumpur,Malaysia
ACPetare
IndianInstituteofTechnologyIndore,Indore,India QiaoXu FineOpticalEngineeringResearchCenter,Chengdu, China
QinghuaZhang FineOpticalEngineeringResearchCenter,Chengdu, China
MMRatnam UniversitiSainsMalaysia,NibongTebal,Penang, Malaysia
NSaklakoglu CelalBayarUniversity,Manisa,Turkey
TSaleh
InternationalIslamicUniversityMalaysia,Kuala Lumpur,Malaysia
SMSapuan UniversitiPutraMalaysia,Serdang,Malaysia
AADSarhan UniversityofMalaya,KualaLumpur,Malaysiaand AssiutUniversity,Assiut,Egypt
CONTENTSOFALLVOLUMES
VOLUME1 – FinishMachiningandNet-ShapeForming
ConventionalFinishMachining
1.1FactorsAffectingSurfaceRoughnessinFinishTurning MMRatnam 1
1.2EffectofCuttingVariablesonBoringProcess:AReview SALawal,MBNdaliman, KCBala,andSSLawal
1.3FinishMachiningofHardenedSteel SKChoudhuryandSChinchanikar
1.4ReviewofGearFinishingProcesses NKJainandACPetare
1.5RoboticPolishingandDeburring FengfengJeffXi,TianyanChen,andShuaiGuo
1.6PrecisionGrinding,Lapping,Polishing,andPost-ProcessingofOpticalGlass YaguoLi, QinghuaZhang,JianWang,QiaoXu,andHuiYe
AdvancesinFinishMachining
1.7TechniquestoImproveEDMCapabilities:AReview HMarashi,AADSarhan,IMaher, andMSayuti
1.8NaturalFiber-ReinforcedComposites:Types,Development,ManufacturingProcess,and Measurement SMSapuan,KFTamrin,YNukman,YAEl-Shekeil,MSAHussin,and SNAAziz
1.9EffectofElectricalDischargeEnergyonWhiteLayerThicknessofWEDMProcess IMaher, AADSarhan,andHMarashi 231
1.10Micro-EDMDrillingofTungstenCarbideUsingMicroelectrodewithHighAspectRatioto ImproveMRR,EWR,andHoleQuality MHourmand,AADSarhan,MYNoordin,and MSayuti
1.14LaserPeeningofMetallicMaterials SGencalpIrizalpandNSaklakoglu
1.15MicroPlasticPartFillingCapabilitiesthroughSimulationandExperiment:ACaseStudyon MicroGearShape MAzuddin,ZTaha,andIAChoudhury
1.16Net-ShapeMicrofabricationTechniquebyMicrometalPowderInjection Molding AAAbdullahi,NNahar,MAzuddin,andIAChoudhury
1.17ReviewofMiniatureGearManufacturing NKJainandSKChaubey
2.1FundamentalsofHeatTreatingMetalsandAlloys
2.2HardenabilityofSteel AKBhargavaandMKBanerjee
2.3Carburizing:AMethodofCaseHardeningofSteel MMABepari
2.4SurfaceHardeningbyGasNitriding KFarokhzadehandAEdrisy
2.5LaserBeamProcessingforSurfaceModifications BSYilbas
2.6SurfaceInductionHardening JBarglikandASmalcerz 154
2.7RecentAdvancesinMechanicalSurfaceTreatment SIsmail,QAhsan,and ASMAHaseeb 171
2.8HeatTreatmentofCommercialSteelsforEngineeringApplications MKBanerjee
2.9HeatTreatmentofToolSteels RAMesquita,CABarbosa,andARMachado 214
2.10HeatTreatmentofCastIrons IChakrabarty 246
2.11ThermalTreatmentforStrengtheningTitaniumAlloys ASinha,SSanyal,and NRBandyopadhyay 288
2.12HeatTreatmentofAluminumAlloys HMMARashedandAKMBazlurRashid
2.13SolutionizingandAgeHardeningofAluminumAlloys GQuan,LRen,andMZhou
2.14Heat-TreatingCopperandNickelAlloys AKBhargavaandMKBanerjee 398
2.15CryogenicTreatmentofEngineeringMaterials TSlatterandRThornton
VOLUME3 – SurfaceCoatingProcesses
3.1ElectrolessPlatingofPdBinaryandTernaryAlloysandSurfaceCharacteristicsfor ApplicationinHydrogenSeparation AMTarditi,MLBosko,andLMCornaglia 1
3.2TuningoftheMicrostructureandSurfaceTopographyofHot-DipGalvanized Coatings SMAShibliandRManu 25
3.3SurfaceFinishCoatings PSahoo,SKDas,andJPauloDavim
3.4ResidualStressesinThermalSprayCoating AFMArif,KSAl-Athel,andJMostaghimi 56
3.5LaserTexturingofMaterialsandSurfaceHydrophobicity BSYilbas 71
3.6SurfaceTexturePropertiesofCo–NiAlloysFormedwithUnipolarandBipolar Plating JVazquez-Arenas,IRomero-Ibarra,RHLara,andFSSosa-Rodríguez 86
3.7HVOFCoatingofNickelBasedAlloys:SurfaceandMechanicalCharacteristics BSYilbas 96
3.8Laser-Based3DPrintingandSurfaceTexturing ASelimisandMFarsari 111
3.9HydrophobicityandSurfaceFinish AOwais,MKhaled,andBSYilbas
3.10AtomizersandFinishPropertiesofSurfaceCoatings RRayandPHenshaw
3.11GasNitridingofH13ToolSteelUsedforExtrusionDies:Numericaland ExperimentalInvestigation SSAkhtar,AFMArif,andBSYilbas
3.12Hot-DipGalvanizingProcess FOzturk,ZEvis,andSKilic
3.13FinishingandPost-TreatmentofThermalSprayCoatings MMVerdian
3.14HighVelocityOxy-FuelSprayingandSurfaceFinish HSingh,MKaur,and NBala
3.15ElectrolessPlatingasSurfaceFinishinginElectronicPackaging MAAzmahHanim
3.16HardCoatingsonCuttingToolsandSurfaceFinish HCaliskan,PPanjan,and CKurbanoglu
3.17TopologicalEvaluationofSurfacesinRelationtoSurfaceFinish PDemircioglu
CONTENTSOFVOLUME1
Preface
IntroductiontoFinishMachiningandNet-ShapeFormingxix VOLUME1 – FinishMachiningandNet-ShapeForming
ConventionalFinishMachining
1.1FactorsAffectingSurfaceRoughnessinFinishTurning MMRatnam 1
1.2EffectofCuttingVariablesonBoringProcess:AReview SALawal,MBNdaliman, KCBala,andSSLawal
1.3FinishMachiningofHardenedSteel SKChoudhuryandSChinchanikar
1.4ReviewofGearFinishingProcesses NKJainandACPetare
1.5RoboticPolishingandDeburring FengfengJeffXi,TianyanChen,andShuaiGuo 121
1.6PrecisionGrinding,Lapping,Polishing,andPost-ProcessingofOpticalGlass YaguoLi, QinghuaZhang,JianWang,QiaoXu,andHuiYe 154
AdvancesinFinishMachining
1.7TechniquestoImproveEDMCapabilities:AReview HMarashi,AADSarhan,IMaher, andMSayuti
1.8NaturalFiber-ReinforcedComposites:Types,Development,ManufacturingProcess,and Measurement SMSapuan,KFTamrin,YNukman,YAEl-Shekeil,MSAHussin,andSNAAziz
1.9EffectofElectricalDischargeEnergyonWhiteLayerThicknessofWEDMProcess IMaher, AADSarhan,andHMarashi
1.10Micro-EDMDrillingofTungstenCarbideUsingMicroelectrodewithHighAspectRatio toImproveMRR,EWR,andHoleQuality MHourmand,AADSarhan,MYNoordin,and MSayuti
1.14LaserPeeningofMetallicMaterials
1.15MicroPlasticPartFillingCapabilitiesthroughSimulationandExperiment:ACaseStudyon MicroGearShape MAzuddin,ZTaha,andIAChoudhury
1.16Net-ShapeMicrofabricationTechniquebyMicrometalPowderInjection Molding AAAbdullahi,NNahar,MAzuddin,andIAChoudhury
1.17ReviewofMiniatureGearManufacturing NKJainandSKChaubey
PREFACE
Finishmanufacturingprocessesare finalstageprocessingtechniqueswhicharedeployedtobringproductstoastagewherethey arereadyformarketingandputtinginservice.Overrecentdecades,anumberof finishmanufacturingprocesseshavebeen developedbyresearchersandtechnologists.Someofthesenewprocesseshavebeendocumentedandillustratedbothindividually andcollectivelyinrelationtoapplicationinspecificareas.Theadvancementoftoolsofphysicshasresultedinconsiderable changestotheseprocesses,andtheprecisionwithwhichtheycanbeapplied.Thereportingofthesedevelopmentsaresometimes fragmentary,andthisreferenceworkprovidesamoreconnectedandthoroughreviewoftheseprocesses.
ComprehensiveMaterialsFinishing istheprimaryreferencesourceforresearchersatdifferentlevelsandstagesintheircareerboth inacademiaandindustry.Thisreferenceworkencompassestheknowledgeandunderstandingofmanyexpertsintoasingle, comprehensivework.Containingacombinationofreviewarticles,casestudies,andresearch findingsresultingfromresearchand developmentactivitiesinbothindustrialandacademicdomains,thisreferenceworkfocusesonhowsomeofthese finish manufacturingprocessesareadvantageousforabroadrangeoftechnologies.Theseincludeapplicability,energyandtechnological costs,andpracticabilityofimplementation.Awiderangeofmaterialssuchasferrous,nonferrous,andpolymericmaterialsare covered.
Thisworkdetailsthethreeforemostanddistincttypesof finishingprocesses:surfacetreatment, finishmachiningprocesses,and surfacecoatingprocesses.Surfacetreatmentreferstopropertiesofamaterialbeingmodifiedwithoutotherwisechanging thephysicaldimensionsofthesurface.Finishmachiningprocessesinvolveasmalllayerofmaterialbeingremovedfromthe surfacebyvariousmachiningtypeprocessestorenderimprovedsurfacecharacteristics.Surfacecoatingprocessesarewhere thesurfacepropertiesareimprovedbyadding finelayer(s)ofmaterialswithsuperiorsurfacecharacteristicstoimprovetheservice lifeofthesurfacebeingcoated.Eachprimarysurface finishingprocessispresentedinaseparatevolume,comprisingchapterson manyofthefollowingrelevantspecificprocessesasfollows:
Volume1:FinishMachiningandNet-ShapeForming:developmentsinconventional finishmachiningprocesses(honing,lapping, polishing,burnishing,anddeburring), finegrinding,freeEDM,laser finishing,electricaldischargegrinding(EDG),electrochemicalhoning(ECH),electrochemicaldischargegrinding(ECDG),electrochemicalgrinding(ECG),electrochemicalturning (ECT),micro-machiningprocess,andhigh-speedmachining.
Volume2:SurfaceandHeatTreatmentProcesses:Thiscontainsaspectsofheattreatments,stressrelieving,annealing,normalizing, hardening,tempering,austempering,martempering,carburizing(pack,liquid,gas,andpostcarburizingtreatments),nitriding (gasandplasma),saltbath(boriding,chromizing,cyaniding,andcarbonitriding),phasetransformationoftheoutersurface (induction, flame,laser,electronbeam,andanodizing).
Volume3:SurfaceCoatingProcesses:Plating(electroplating,alloys(bronze/brassandothers),chromium,densechromium, copperandtin,gold,silverandotherpreciousmetals,zincandnickel,electroforming,electrolessnickel,hotdipgalvanizing, selective/brushplating,surface finishcoatings,airspraypainting,andchemicalvapordeposition(CVD)).
Finishingprocessesareatthecoreofsuccessfulproductionofmarketableproductsandaddressrecentprogressinmaterials finishingtechnologiesandscienceaswellascoveringrecentdevelopmentsinspecificmanufacturingprocessesinvolvedwith finishingofproductsforapplicationsinallareasofengineering,biomedical,environmental,healthandsafety,andmonitoring andcontrol.Thein-depthstudyofthese finishingprocessesaspresentedinthesevolumeswillassistscientistsandengineersinthe selection,design,andusageofmaterials,whetherrequiredinsmall-orlarge-scaleusesacrossindustries.
Theinitiationsforthisprojectbeganin2014andbyJanuary,2015,Ihadselectedthevolumeeditors – BekirYilbas,Imtiaz Choudhury,andShahjahanMridhaandwemetwithGemmaTomalin,JoanneWilliams,andGrahamNisbetattheElsevieroffice inOxfordto finalizethetableofcontentsandplantheproject.Throughout2015,thevolumeeditorsandIworkedresolutelyto selecttopicstobecovered,inviteauthors,andreviewtheirmanuscripts,eventuallygettingallcontentreadyforproductionby theendof2015.In2016,authorsreturnedtheirproofcorrectionsand final fileswereproduced.Tocreateaworkofthisscale,the mostin-depthreferenceeverpublishedonmaterials finishingprocessesandsurfaceengineering,reliesonacollaborationof authors,editors,andtheteamatElsevier.Iwouldliketothankthemanydedicatedauthors,whosecontributionswillbean essentialreferenceformaterialsscientistsandengineers.Eachchapterhasbeenreviewedbyoneofthevolumeeditors,leading expertsintheir fields,whoseknowledgeandexpertisehaveprovedinvaluable.Iamindebtedtoeachvolumeeditorandtheir dedicationtomakingtheirvolumeanexhaustiveandrelevantresourceforthescientificcommunityformanyyearstocome.Finally, onbehalfofmyselfandthevolumeeditors,IwouldliketothankGemmaTomalinandJoanneWilliamsatElsevierfortheir support,cooperation,andgoodhumorthroughoutthisproject – fromthe firstmeetinginearly2015,tothepublicationmid-2016.
MSJHashmi Editor-in-Chief
DublinCityUniversity,Dublin,Ireland
1.1FactorsAffectingSurfaceRoughnessinFinishTurning
MMRatnam, UniversitiSainsMalaysia,NibongTebal,Penang,Malaysia
r 2017ElsevierInc.Allrightsreserved.
1.1.1Introduction
1.1.1Introduction
Turningisacommonmetalremovalprocessinwhichasinglepointcuttingtoolismovedrelativetoarotatingcylindrical workpieceonamachinetool.Themajorapplicationofturningisintheremovalofbulkmaterialfromtheworkpieceto achievetherequireddimensions.Thisisknownasrough turning,orsimplyasroughing.However,turningisincreasinglyusedtoproducegoodsurface finishinprocessesknown as finishturning.Thisisdonetypicallytoavoidorreduce secondaryprocessessuchasgrindingorlapping,thussaving productioncosts.Finishturningusuallyinvolvesturningusing thetiporthecurvednoseareaofthecuttingtoolinsert.The depthofcutisusuallylessthanthenoseradiusofthecutting tool.Theobjectiveof finishturningistoproduceproductsof high-dimensionalprecisionwithgoodsurface finishquality.
Thesurface finishqualityofaproductisusuallyassessedin termsofitssurfaceroughness.Theroughnessofamachined surfaceisconsideredasoneofthemaincharacteristicsof theproductasitgreatlyinfluencesthefatiguelife,coefficientof friction,wearresistance,andsubsequentlythereliablefunction oftheproductduringservice.Therearemanyfactorsthataffect thesurface finishqualityofaworkpieceinturning.Thesefactors canbebroadlydividedintothefollowingfourmaincategories:
1.Factorsduetomachiningconditions,suchasdryturning, wetturning,typeofcutting fluid,methodofcutting fluid application,chattervibration,andmachinetoolrigidity.
2.Factorsduetocuttingtoolparameters,suchastoolnose radius,noseangle,tooledgepreparation(honedor chamfered),rakeangle,sideedgecuttingangle,cuttingtool material,andtoolcoating.
3.Factorsduetomachiningparameters,suchasfeedrate, cuttingspeed,anddepthofcut.
4.Factorsduetoworkpiecematerialproperties,suchashardness,microstructure,grainsize,composition,andinternal defects.
Theresearchworkcarriedoutinthepasttounderstand howthevariousfactorsaffectthesurface finishqualityofthe workpieceinturningisreviewedinthischapter.Agreater emphasisisgiventothemorerecentworkinthisrapidly advancing fieldwhichininfluencedbythedevelopment ofmoderninstrumentationanddataanalysistechniques. Previousworkstooptimizetheprocessparameterstoobtain thebestsurface finishandtopredictthesurfaceroughnessare reviewed.Potentialareasforfurtherresearchthatcanprovide newinsightsintotheeffectofthevariousfactorsinmoredetail aresuggestedattheendofthechapter.
1.1.2FactorsduetoMachiningConditions
1.1.2.1FactorsduetoCuttingFluidsandMethodofFluid Application
Cutting fluidsserveaslubricantsaswellasheatremovalagents duringturning.Theyareusedtoreducefrictionandtoolwear, improvesurface finish,reduceenergyconsumption,reduce thermaldistortions,facilitatechipremoval,reducetendency ofbuilt-upedge(BUE)formation,andprotectthenewly machinedsurfacefromenvironmentalcorrosioneffects.Cutting fluidsarealsoknownasmetalworking fluids,coolants, orsimplyaslubricants.Adetailedtreatmentofthesubjecton metalcutting fluidsisgivenbyByres.1
Extensiveresearchhasbeencarriedoutinthepastthree decadestostudytheeffectofthetypeofcutting fluidandthe methodof fluidapplicationonthesurface finishofvarious typesofworkpiecematerialsduringturning.Thecutting fluids usedinthesestudiescanbeclassifiedintofourmaincategories accordingtotheirchemicalformulation.Theyaremineraloils, solubleoils(emulsifiedoils),synthetic(chemical) fluid,and semisynthetic fluids.Cuttingoilswithoutfurtherdilutionor additivesareknownasneatoilorstraightoil.Besidesmineral andchemical-based fluids,vegetableoils,beingbiodegradable,
havethepotentialtoreducewastetreatmentcostsandhealth hazardsassociatedwiththepetroleum-basedoils.Therefore, severalresearchershaveinvestigatedtheeffectofvarious bio-basedcutting fluidsonthesurface finishqualityinturning. Thefourcommonmethodsofapplyingthecutting fluidto thecuttingzoneareby flood filling,jetimpingement,mist,and minimumquantitylubricant(MQL).Theeffectsofthe fluid applicationmethodsonthesurfaceroughnessofthe finished workpiecehavebeenstudiedbyanumberofresearchers.
Theeffectofdifferentcutting fluidsonsurface finishand toolwearduringturningofAISI304steelusingacarbidetool wasinvestigatedbyXaviorandAdithan.2 Theauthorsstudied threetypesofcutting fluids,namelysolubleoil(emulsion), neat(mineral)cuttingoil,andcoconutoil.Coconutoilwas chosenasoneofthecutting fluidsduetoitsloweronset temperatureofthermaldegradationcomparedtosunflower andsesameoils.3 Intheirmachiningexperimentsthefeed ratewasvariedfrom0.1to0.35mmrev 1.Theirresults showedthatatalowfeedrate(0.2mmrev 1)coconutoiland solubleoilproducedsimilarsurface finishbutneatoilresulted inslightlyhigherroughnessvalues.Athigherfeedrates (0.35mmrev 1)coconutoilproducedthebestsurface finish whencomparedtotheothertwo fluids.Adifferenceinthe averageroughness(Ra)of1.0 mmwasobtainedatafeedrate of0.35mmrev 1 whencomparingturningcarriedoutusing straightoilandcoconutoil.Thisobservationwasattributedto themuchlowertool flankwearwhenthemachiningwas carriedoutusingcoconutoilasthecutting fluid.Theauthors reportedthatthelowerviscosityofcoconutoilallowedeasier flowofthecutting fluidthusenablingbetterremovalofthe heatatthetool–workpieceinterface.
Lawal etal 4 preparednewoil-in-wateremulsioncutting fluidsbymixingthreedifferenttypesofoils(palmkerneloil, cottonseedoil,andmineraloil)separatelywithwaterand additivessuchasanticorrosionagent,antioxidant,andbiocide.Thewater-to-oilratiousedforeachcasewas9:1.The turningtestswereperformedonAISI4340alloysteel.Their resultsshowedageneraltrendofimprovementofsurface roughnesswhenusingpalmkerneloilandcottonseedoilbasedcutting fluidscomparedtomineraloil-basedcutting fluid.Theauthorsattributedthis findingtothereduction incuttingforcewhenusingbio-based fluids.Thisinturn wasexplainedintermsoftheformationofahigh-strength boundary filmthatresultedfromthehighproportionoffatty acidsinthebio-based fluids.
MQLreferstotheuseofaverysmallquantityofcutting fluid,typicallyat flowratesof50–500mlh 1,whichisdirected tothecuttingzonevianozzlesorchannelsbuiltinsidethetool holder.TheconceptofusingMQL(alsoknownasnear-dry lubricationormicro-lubrication)inmachiningwassuggested morethanadecadeagoasameansofovercomingthe problemsrelatedtotheairbornecutting fluidparticles thatposehealthhazards.MQLalsoleadstosignificantsavingin cutting fluidsandreducesworkpiece/tool/machinecleaning cycletime.Khan etal 5 studiedtheeffectsofMQLusingvegetableoil-basedcutting fluidontheturningperformanceofAISI 9310alloysteelcomparedtocompletelydryandwetturning. TheMQLwassuppliedbypassingairathighpressureintoa mixingchamberthatdrewacontrolledamountof fluid.The mixturewasdirectedathighvelocitytothechip–toolinterface
throughanozzle.Theirresults(Figure1)showthatturning usingMQLproducedbettersurface finishcompared todryorwetturning.After45minofmachiningtimean improvementof29%intheaverageroughnesswasobserved comparedtothewetturning.Theimprovementobserved, however,dependedonthework-toolmaterialsandwas achievedmainlybycontrollingthedeteriorationoftheauxiliary cuttingedgebyabrasion,chipping,andformationofBUE.The surfaceroughnessimprovedeffectivelyduetothereductionof wearanddamagetothetooltipduetotheapplicationofMQL. deAngeloSanchez etal 6 investigatedtheeffectofdifferent methodsofcutting fluidapplicationontheturningof difficult-to-cutmachinesteel(SAEEV-8).Theauthorcomparedthreedifferentmethodsof fluidapplication,namely overhead flood filling,MQL,andpulverization.Thecutting fluidusedforthe flood fillwasasemisynthetic fluidwhilethat usedforMQLwasvegetableoil.Pulverizationwasachievedby usingahigh-pressurenozzle.Amongthemethodscompared theauthorsfoundthattheapplicationofcutting fluidjet directedtothechip–toolinterfaceresultedinincreasedtool lifeanddecreasedcuttingforce,thusimprovingthesurface finish.However,whenthereductionintoolwearisthemain objectivetheauthorsreportedthattheconventionalmethod of flood fillingwasmoreefficient.Shokoohi etal 7 studiedthe combinedeffectofMQLandprecoolingoftheworkpieceon surfaceroughnessandothereffectssuchaspowerconsumptionandchipformation.Themachiningwascarriedouton hardenedandtemperedAISI1045steel.Theworkpiecewas precooledusingCO2 asthecryogenicagent.Thecutting fluid wasmadebymixingsunfloweroilwithwaterandasmall amountofantibacterialagent.Theauthorsreportedthat theapplicationoftheprecoolingprocessalongwithusing MQLwiththenewcoolantresultedintheimprovementof thesurface finish.Thiswasattributedtothecoldercutting zoneduetotheefficientpenetrationoftheoilintothe tool–workpieceinterface.
Sincetheconventionalcoolingmethods,suchas flood fillingandhigh-pressurejets,areunabletoensurethepenetration ofthe fluidtothechip–toolinterface,Sohrabpoor etal 8 used MQLstrategyduringtheturningofAISI4340stainlesssteel. Theauthorscomparedfourstrategiesoflubricationnamelydry
Figure1 Effectofvariouscoolingconditionsonsurfaceroughness.5
