https://orcid.org/0000-0002-0021-6026
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ABSTRACT
This paper elucidates the outcome of machining factors specifically cutting velocity, feed rate and depth of cut on the machining characteristics such as surface roughness and tool-work interface temperature while turning cylindrical AISI 52100 steel alloy components in dry and microlubrication machining conditions. The experiments are designed based on the Taguchi’s L25(53) orthogonal array and conducted on an All Geared Lathe, simultaneously the tool-work interface temperature was observed using a K-type tool-work thermocouple and subsequently, a mathematical model was developed for the tool-work interface temperature values through regression analysis. The surface roughness of the turned steel alloy components is deliberated by means of a precise surface roughness apparatus. A prediction model in lieu of average surface roughness is created by means of nonlinear regression examination with the aid of MINITAB software. The most favourable machining settings are recognised by Taguchi’s method and verified with a confirmation trial. The results revealed that machining under microlubrication condition exhibited lesser temperature at the tool-work interface and the quality of the machined components also exhibits lesser roughness when compared with components of dry machining condition.
Nomenclature
| f | = | Feed rate in mm/rev |
| v | = | Cutting velocity in m/min |
| d | = | Depth of cut in mm |
| CBN | = | Cubic Boron Nitride |
| Rad | = | Average surface roughness for dry machining condition in µm |
| Ram | = | Average surface roughness for microlubrication machining condition in µm |
| Td | = | Tool-work interface temperature for dry machining condition in 0C |
| Tm | = | Tool-work interface temperature for microlubrication machining condition in 0C |
| 0C | = | Degree Celsius |
| S/N | = | Signal to Noise |
| R | = | Correlation coefficient |
| Mn | = | Manganese |
| C | = | Carbon |
| S | = | Sulphur |
| P | = | Phosphorus |
| Si | = | Silicon |
| Fe | = | Iron |
| AISI | = | American Iron and Steel Institute |
Disclosure statement
No potential conflict of interest was reported by the authors.
Additional information
Notes on contributors
S. Rajarajan
S. Rajarajan has obtained his bachelor's and master's degree in Mechanical Engineering from Anna University and Ph.D. from Karpagam Academy of Higher Education, India. His area of interest includes machining of steel and parametric optimisation.
C. Ramesh Kannan
C. Ramesh Kannan has obtained his bachelor's, master's and Ph.D. in Mechanical Engineering from Anna University and Ph.D. from Karpagam Academy of Higher Education. His area of interest includes machining of steel and parameter optimization. He has about 19 years of teaching experience and 8 years of research experience. He has various publications in both national and international journals. He is currently working as an Associate Professor in the Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore, India. His area of interest includes machining of steel in the cryogenic environment and parametric optimisation.
Milon Selvam Dennison
Milon Selvam Dennison received his bachelor's in Mechanical Engineering from Bharath Institute of Higher Education and Research, Chennai, India, master's in Manufacturing Engineering from Anna University, India and a Ph.D. from Karpagam Academy of Higher Education, India in 2007, 2009 and 2018 respectively. Presently, he is doing research in the field of metal cutting fluids. He has various publications in both national and international journals. He is currently working as Senior Lecturer in the Department of Mechanical Engineering, Kampala International University, Uganda. His current research interests include manufacturing of materials, metal cutting, metal cutting fluids and machining optimisation.