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Research Papers

Flank Wear Characterization in Aluminum Alloy (6061 T6) With Nanofluid Minimum Quantity Lubrication Environment Using an Uncoated Carbide Tool

[+] Author and Article Information
M. S. Najiha

Faculty of Mechanical Engineering,
Universiti Malaysia Pahang,
Pekan 26600, Pahang, Malaysia
e-mail: najihahassany@gmail.com

M. M. Rahman

Faculty of Mechanical Engineering,
Universiti Malaysia Pahang,
Pekan 26600, Pahang, Malaysia;
Automotive Engineering Centre,
Universiti Malaysia Pahang,
Pekan 26600, Pahang, Malaysia
e-mail: mustafizur@ump.edu.my

A. R. Yusoff

Faculty of Manufacturing Engineering,
Universiti Malaysia Pahang,
Pekan 26600, Pahang, Malaysia
e-mail: razlan@ump.edu.my

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 6, 2014; final manuscript received March 6, 2015; published online September 9, 2015. Assoc. Editor: Patrick Kwon.

J. Manuf. Sci. Eng 137(6), 061004 (Sep 09, 2015) (7 pages) Paper No: MANU-14-1358; doi: 10.1115/1.4030060 History: Received July 06, 2014

This study is focused on the categorical analysis of flank wear mechanisms in end milling of aluminum alloy AA6061 with minimum quantity lubrication (MQL) conditions using nanofluid. Wear mechanisms for the water-based TiO2 nanofluid with a nanoparticle volume fraction of 1.5% are compared with conventional oil-based MQL (0.48 ml/min and 0.83 ml/min) using an uncoated cemented carbide insert. Micro-abrasion, micro-attrition, and adhesion wear leading to edge chipping are identified as the main wear mechanisms. Aluminum deposits on the tool flank surface are observed. Results show that the water-based nanofluid shows potential as a capable MQL cutting media, in terms of tool wear, replacing the conventional oil-based MQL.

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References

Figures

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Fig. 9

Flank wear comparison for MQL and nanofluid MQL conditions

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Fig. 2

Tungsten carbide (WC)–Co 6% insert properties and geometry (M/s CERATIZIT)

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Fig. 1

TEM image of TiO2 nanoparticles

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Fig. 8

(a) Micro-area selected on main cutting edge; and (b) micro-area selected at some distance from the cutting edge of an uncoated WC–Co 6.0% tool at depth of cut = 3.0 mm, speed = 5500 rpm, feed rate = 440 mm/min, MQL flow rate = 0.48 ml/min, nanoparticles 1.5% fraction

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Fig. 7

Abrasion and attrition wear on: (a) nose region; and (b) on main cutting edge for an uncoated WC–Co 6.0% tool at depth of cut = 3.0 mm, speed = 5500 rpm, feed rate = 440 mm/min, MQL flow rate = 0.48 ml/min, nanoparticles 1.5% fraction

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Fig. 6

(a) EDX spectra for the micro-area selected on the tool cutting edge; (b) micro-area selected for the analysis of elements away from the main cutting edge on an uncoated WC–Co 6.0% tool at depth of cut = 3.0 mm, speed = 5300 rpm, feed rate = 440 mm/min, MQL flow rate = 0.83 ml/min, nanoparticles 1.5% fraction

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Fig. 5

(a) Abrasion marks and attrition on nose region; and (b) edge fracture of the tool at depth of cut = 3.0 mm, speed = 5300 rpm, feed rate = 440 mm/min, MQL flow rate = 0.83 ml/min, nanoparticles 1.5% fraction

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Fig. 4

(a) Edge fracture; (b) micro-abrasion and micro-attrition; and (c) energy-dispersive X-ray spectroscopy analysis (EDX) pattern for element composition at depth of cut = 3.0 mm, speed = 5500 rpm, feed rate = 440 mm/min, MQL flow rate = 0.48 ml/min

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Fig. 3

(a) Micro-attrition and micro-abrasion wear processes; (b) and (c) adhesion and fracture on the edge; and (d) EDX pattern for element composition for uncoated WC–Co 6.0% tool at depth of cut = 3.0 mm, speed = 5300 rpm, feed rate = 440 mm/min, MQL flow rate = 0.83 ml/min

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