Abstract--- In present investigation, the effect of that conventional insert to the wiper insert as a significant
lubrication on tool wear of single point cutting tool insert. The class of cutting tool to give effective surface roughness by
AISI4340 steel is turned with single point cutting tool insert different amplitude parameters. High feed rate of cutting tool
with different lubricant Dry, Minimum Quantity Lubrication with inserts give micron level machined surface and provide
and Nano. Speed, feed, depth of cut are the input parameters similar surface roughness when compared to conventional
at three levels and crater wear are considered as output insert. (Erween A. Rahim and Hiroyuki sasahara 2010) [5],
response. On comparing these lubricants, Nano fluids seem to Compared the palm oil and synthetic ester on surface integrity.
exhibit a better novel property that made it applicable to use it That result in MQL has more benefit in palm oil on Surface
as a heat transfer medium in cutting zone. As a result carbide properties. The mechanical property of machined surface has
cutting tool insert with Nano lubrication have superior wear altered but Hardness is increased than bulk material hardness.
resistant followed by the Minimum Quantity Lubrication and The palm oil is better than SE in terms of micro-hardness and
Dry. effective lubrication and cooling due to high viscosity (Y.M
Keywords--- Tool Wear, Lubricants, Turning Process. Shashira. 2010) [6]. Say vegetable oil and soya bean,
sunflower oil and rapeseed had relevant properties as cutting
fluids. To increase these properties the poor low temperature
I. INTRODUCTION property and resistance to oxidative degradation by additives,
chemical modification and generic modification is done. The
HE metal cutting is the major task. (Richard Harvert.
T 2014) [1] It deals with the Surface Roughness as
important as geometry and or Mechanical property of
result were attained under metal working condition and
studied oils revealed that the vegetable oil have large scope of
utilization. (Khaider Boucha 2014) [7]. worked on the
Material. The desired functional and frictional behaviors were experimental study on hard turning of steel the process
described in a better way by skewness (Rsk) and kurtosis parameters and performance characteristic were optimized
(Rku) as statistical parameters of surface roughness rather than using ANOVA, generic algorithms, Gray taguchi methods and
average roughness (Ra) and surface height (Rz). Statistical statistical analysis and showed that statistic and stochastic
parameters of Surface had been analyzed in mass production approaches bring reliable methodologies to improve the hard
of aluminum alloys by turning process shows it only on tool turning process and they are very suitable for solving the
Geometry. (Milos Madic 2011) [2] Produced the predictive optimization problem with multiple performances. (Kennth M.
modelling and optimization of machining process. By Using Doll 2011) [8]. proposed work on chemically modified
ANN prediction method the Cutting force components using vegetable oil using surfactant system and found that epoxidase
high prediction accuracy. Depth of cut feed rate influence oil is stable oil in water. The best surfactants have HLB value
main cutting force, feed force, passive force positively and slightly above. He concluded that, drops of the stabilized
Cutting edge angle influences cutting force directly. The feed emulsion are extremely smaller in all cases though those
force negatively. (M. Grzesik. 2005) [3]. Dealt with green emulsions had similar stabilities as inspected visually. Thu
manufacturing that include dry and hard, often high-speed, studies have demonstrated that emulsion stability is not always
machining Technology. With lower values of skew at lower correlated with droplet size, but dependent on many other
feeds, surfaces generated experiences better bearing factors like oils are highly effective lubricants, even at only
properties. Wiper inset had Comparable surface roughness to 1% oil. This shows that of all of the lubricants in the system,
the effect at lower feed rate (A. Esteves Correiam 2011) [4]. only the small amount of lubricant at the surface gives the
Used machining technology on Surface roughness and find wear reduction where the emulsion acts as the delivery
system. (D.I lalwani 2008) [9]. presented the effect of cutting
forces based on response surface methodology on turning of
C. Rameshkannan, Faculty, Department of Mechanical Engineering, steel. The coated ceramic tool shows main contribution of
Anna University Regional Campus, Madurai, India. E-mail:
rameshkannan@autmdu.ac.in
cutting parameters, the feed force, thrust force, cutting force
P. Padmanabhan., Professor, Department of Mechanical Engineering, model and surface roughness model. While cutting speed and
V.V College of Engineering, Tisaiyanvilai. India. E-mail: depth of cut are feed nearer their high level of desired range
ajaipalani@yahoo.co.in and feed rate is at low level of the experiment range better
G. Arundeepan, P.G Scholar, Department of Mechanical Engineering,
Anna University Regional Campus, Madurai, India. E-mail:
surface roughness can be attain. (Kuan-Ming li, Shih-yen
arun.deepan66@gmail.com Chou 2010) [10]. present performance of minimum quantity
DOI:10.9756/BIJIEMS.7622 lubrication technique in Nano also known as near dry
machining refers to cutting fluids in tiny quantity. He (R. suresh 2012) [16].Studies conducted on hard turning with
compared MQL and Complete Dry conditions were to give multicoated carbide tool to get reduced processing cost,
better mechanical performance. Result were Reduction in increase in productivity and material property. The abrasion of
flank wear length on all cutting conditions and expected to tool in all cutting condition was principle wear. Thus resulted
improve tool life. Surface roughness measurement when in the feed rate had physical as well as statistical influence on
milled on steel show. Minimum quantity lubrication shows machining force. The sufficient chip formation process cant
better surface roughness in terms of dry cutting. The be achieved for particular cutting force to machining followed
relationship between tool wear and burr formation, diminution by the depth of cut, cutting speed,low feed rate.The multiple
under MQL condition is attributed to low wear in Nano- regressions were obtained to predict tool wear and surface
cutting .The increase in oil mist velocity and reduction of oil roughness. (N. talib, E.A Rahim 2016) [17]. Researched on
drop size achieved by effect of air flow rate in micro-milling effect of tribological behavior of metal working fluid is reduce
under MQL.(R. Ferreira 2015) [11]. Researched Wiper wear and friction. It made from mineral oil cause ecology and
geometry has as main objective obtained a smoother surface human health. By Minimum quantity lubrication had done for
after the cutting process. There is no leaning for surface lubrication in orthogonal cutting processing for MJO5. It gives
roughness while analyzing have slightly better performance of better cutting force compared to synthetic Easter CJO need to
wiper tools was observed for the flank wear. The results varied undergo chemical modification process in order to affects the
widely depending on the machining length. Flank wear and thermal and oxidation stability. (Prernasingh Chauhan, V.K
surface roughness showed no relation. The flank wear was Chhibber 2013)[18]. Discussed about non-Edible oil as a
measured in the corner of the tool using the indicator VBC. No source of biolubricants found that have great importance on
catastrophic failure was obtained during the tests. Some tools the emphasis on environmental friendly lubricant. The
had evolution of the surface roughness tends to reach higher ecofriendly vegetable oil compared by property of synthetic
values when tool wear is higher. (VinayakNeelakanthGaitonde Easter, chemically modified Easter to get increased
2010) [12]. conducted comparison between different performance on hydraulic oils, refrigeration oils, chainsaw
performance parameters of cold work tool on turning with lubricants. Most mineral oil based greases had been
different ceramic inserts. Tool wear had high sensitive to formulated easily from vegetable oil based thickener and
cutting speed and feed rate and it have been compared with stabilized vegetable oils. (S.A lalwal, 2013) [19]. proceeded
wiper insert. Ceramic insert has an edge over the other tool for with development of formulation of vegetable oil-based
minimizing wear. Comparison of wiper ceramic insert and networking fluids in turning process. The wear in turning
conventional insert minimize the specific cutting force process by fluids deployed by parameters as thrust force,
irrespective of the feed rate. (Sunday Albert Lawal 2013) [13]. surface roughness, temperature at tool chip interface,
considered cooling application and its importance high Lubrication and cooling are severe on contact process by
temperature generation on the edge of the cutting edge has machining workpiece. Utilization of vegetable oil chemistry of
controlling on influence on wear rate of cutting tool and petroleum-based fluids was positive development. If a fluid
connection of friction between chips. The amount of heat loss has excellent biological and hard water stable shown to be
depends on thermal conductivity of tool, tool shape and unique for many characteristic of lubrication. (Arjun kumar
cooling method. Small reductions in temperature greatly 2015) [20]. conducted critical assessment of lubrication
increase tool life. The heat carried from the cutting zone is technique and give performance and drawback. A colloidal
decreased in use of cutting fluid. Thus result show that mixture of metallic or non-metallic Nano meter sized particles
cryogenic cooling technique gives improved productivity and in a base fluid is called. The Nano fluid (NF) shows to be
product quality. The performance of MQL in machining mixture of metallic or non-metallic Nano meter sized particles
process gives better result especially when use of vegetable oil by collusion the atoms. In the present work, a Nano fluid with
Babur (Ozcelik 2011) [14] done optimization of surface superior thermal and tribological properties is developed by
roughness and performance of four cutting oils and vegetable mixing TiO2 nanoparticles in vegetable oil-water or different
oil on drilling stainless steel. The performance evaluation of machining condition is high lightened that includes minimum
vegetable based cutting oils shows give grate result, compare quantity lubrication using vegetable oil lubricant. Resulted in
to semi-synthetic oil along with mineral based fluids by improved surface roughness of 31% for MQL with vegetable
surface measurement. The spindle speed has less influence on oil lubricant the analysis of surface integrity titanium alloy
surface in drilling but increase in spindle speed gives decrease with carbide coated shows no significant difference between
in surface roughness. (Iturbe 2016) [15]. Conducted cryogenic MQL and conventional method.
machining with MQL is better surface integrity by permitting The main objective of this investigation of tool wear using
alternate to flood cooling since large amount of cutting fluids single point cutting tool insert at different lubrication done
along with improve functional performance of machined during turning of AISI4340 steel. The process parameters are
component. Study of cutting fluid with liquid nitrogen with speed feed and depth of cut are selected as three levels. In this
MQL compared to conventional cutting fluid show that tool study, effects of feed rate, depth of cut and cutting speed are
life achieved it cryogenic and MQL machining for long term given as input parameters to find the cutting force using
in turning operations produce hard surface layer deeper than CNMG120408SMRH13A cutting tools under rough condition.
one induced in conventional machining leads to tool life and This paper has four sections. The first one deals the
poor surface integrity in surface roughness micro structural experimental details of machining, which includes the
damage with conventional cooling. preparation of work materials, machine setup and machining
of work material. The third section comprises modeling by
using Response Surface Methodology. The last one analysis Ring Light (White LED)
includes the simulations and optimization. Dimension & 316 x 455 x 533 (W x D x H), 40 kg
Weight
II. EXPERIMENTAL DETAILS Input Voltage 100 240
Range V (Max. 1.8 A)
A. The Preparation of Work Material
C. Experimental Setup
AISI4340 is selected as work material the shape of 32 mm
diameter, 200mm long. After sizing the work material Table 2: Parameters and their Level
polished by emery paper. Sl.no Parameter/notations/units Parameter Levels
-1 0 1
B. Tool Materials
1 Cutting Speed(N) in rpm 1000 1250 1500
The CNMG120408SMRH13A is selected as single point 2 Feed rate (f) in mm/rev 0.1 0.2 0.3
cutting tool insert during machining of AISI4340 steel. The 3 Depth of cut(d) in mm 0.3 0.4 0.5
schematic diagram of prepared work material sample and The value for flank and crater wear from the experimental
insert are shown in Fig.1. test is shown in Table.2.