Miriyala Veera BhadraRao
Dr. Vasim A. Shaikh
Dr. Bhushan T. Patil
Abstract
Researchers have identified machining as the most versatile manufacturing process as compared to metal forming process due to its ability to get close dimensional control, better surface finish and higher production rate. Minimum Quantity Lubrication (MQL) has been a replacement to conventional flood and dry machining due to optimal coolant usage, good heat dissipation at the cutting zone and ecological safety concerns. C15 steels which are low carbon steels find major applications in production from small pins to large axles and shafts. It has advantage over other materials due to its good strength, low cost, ease of heat treatment and machinability. Many researchers have discussed the economical, environmental and health effects of dry, flood and MQL machining during turning steels. This paper reviews the selection of optimum cutting parameters in turning of steels with dry, flood and MQL cooling with or without nano-material. Critical responses analyzed by some researchers during these studies were tool life, surface roughness, material removal rate, energy utilization, cutting forces and tool-work-piece interface temperature, effects of mist generated during machining, chip morphology, mist concentration analysis and improper disposal of cutting fluids. This paper also reviews tool-work interface temperature and cutting force measurement by computational fluid dynamics (CFD) techniques and finite element analysis (FEA) respectively. Finally, an overview of optimization tools such as response surface methodology (RSM), particle swarm optimization (PSO), Design of Experiments and Taguchi method are put forth to establish proper inter-relationship of factors, levels and responses to solve problems in machining especially, mist pollution, surface improvements and tool life enhancement.
Keywords- Minimum Quantity Lubrication(MQL), Nano-Material, Optimization, Steels, Turning