The pressurised MQCF mist jet reduces the cutting zone contact length, because of its optimised parameters and the better lubricating characteristics of BCF.
During metal cutting processes, intensive friction and high temperature generated at the tool chip interface affect the cutting zone of the tool, by inducing damage and wear.
Relationship between the surface roughness and the flank wear and also between the temperature and the flank wear were found out for indirect measurement of the flank wear through surface roughness and cutting zone temperature.
The optimized results indicate that minimum quantity lubrication using nanofluid (NFMQL) shows promising results over minimum quantity lubrication technique using conventional cutting fluid in terms of cutting zone temperature, and surface roughness.
In the present work, flank wear, surface finish and cutting zone temperature were taken as response (output) variables measured during turning and cutting speed, feed and depth of cut were taken as input parameters.
The performance of the cutting tools was evaluated by cutting tool wear and correlated in terms of material's build-up and friction at the chip-tool interface, chip sliding velocity and cutting zone temperature.
Dimensional deviation first decreases and then increases from level two to three, because fresh wire comes in contact with cutting zone which rapidly increases material erosion.
Open image in new window Fig. 4 SEM micrographs of SAE 5130 steel, adjacent to cutting zone, showing a the apparition of micro-cracks and b deep crack that reach the bulk material.
Apart from these parameters, Current and wire speed have major contribution on dimensional deviation value because wire speed increases, fresh wire comes in contact with cutting zone which rapidly increases material erosion which causes dimensional deviation.
Especially, the interaction between different cutting parameters affects the thermal loads in the cutting zone.
Fluids were directed to the cutting zone by three different techniques: flooding, reduced flow rate and MQL.
