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Öğe Development and potential use of MWCNT suspended in vegetable oil as a cutting fluid in machining of Monel 400(Elsevier, 2023) Ross, Nimel Sworna; Ganesh, M.; Ananth, M. Belsam Jeba; Kumar, M.; Rai, Ritu; Gupta, Munish Kumar; Korkmaz, Mehmet ErdiThe heat dissipation problem that arises when machining difficult to cut materials can be mitigated by using nano-cutting fluids, which have a much higher thermal conductivity value than the basic lubricants. Since the heat carrying capacity of the Minimum Quantity Lubrication (MQL) system is significantly lower than that of other coolants, a number of nano-additives are used to increase its cooling effectiveness. Therefore, this study firstly focuses on the assessment of nano-cutting fluids and their significant efficacy in the machining operation of nickel-based alloys. Multi-walled carbon nanotube (MWCNT) suspended in vegetable oil is compared with distinct cooling environmental conditions namely, dry, MQL and cryogenic carbon dioxide (CO2). The novelty of this work is that the different volume fractions of 0.2 - 1 wt% of MWCNT were dispersed to study the contact angle, viscosity and thermal conductivity of the prepared molecular liquid and then, the potential of MWCNT suspended in vegetable oil is used to evaluate the outcomes of surface roughness (Ra), cutting temperature (CT) and tool wear (Vb) while machining Monel 400 alloy. The outcomes affirmed that employing nano MQL in machining operations resulted in a mean reduction of about 65% in the temperature evolved concerning no coolant condition. Additionally, the use of nanoparticles leads to an improved surface finish and abridged tool wear.Öğe Enhancing surface quality and tool life in SLM-machined components with Dual-MQL approach(Elsevier, 2024) Ross, Nimel Sworna; Mashinini, Peter Madindwa; Mishra, Priyanka; Ananth, M. Belsam Jeba; Mustafa, Sithara Mohamed; Gupta, Munish Kumar; Korkmaz, Mehmet ErdiSelective laser melting (SLM) can produce complex metal components with high densities, thereby surpassing the limitations of traditional machining methods. However, achieving accurate dimensions, geometries, and acceptable surface states in parts fabricated through SLM remains a concern as they often fall short compared to traditionally machined components. As a solution, a hybrid additive-subtractive manufacturing (HASM) method was developed to effectively utilize the advantages of both techniques. In this study, SLM-made 316 L stainless steel was machined under distinct cooling conditions to investigate the effects of roughness and tool wear. After a thorough investigation, the dual-MQL strategy was evaluated and compared with dry and MQL cutting strategies. The findings showed that the dual-MQL condition led to a significant reduction in flank wear by 54-56% and 29-34%, respectively, associated with dry and MQL cutting techniques, making it a highly promising key for machining SLM-made steel components. Machine learning techniques are potential tools for prediction and classification capabilities in machining processes. For milling SLM-made 316 L SS, multilayer perceptron (MLP) proved to be the most effective prediction model and for classification MLP and Random forest performed better.Öğe A new approach of measurement and analysis of PVD - TiAlN coated carbide tools in machining of Monel 400 alloy under hybrid cooling conditions(Elsevier Sci Ltd, 2023) Ross, Nimel Sworna; Gopinath, C.; Sivaraman, V.; Ananth, M. Belsam Jeba; Gupta, Munish Kumar; Korkmaz, Mehmet Erdi; Jamil, MuhammadThis research work focuses on the efficacy of minimum quantity lubrication (MQL) and cryogenic carbon dioxide (CO2) cooling in high-speed machining of nickel-based alloy. CO2 and MQL supplied in the rake face were compared to CO2 and MQL in turning of Monel 400. Tool wear, temperature, surface roughness, and micro -structural assessments were done to compute the cooling influence of distinct approaches. Energy dispersive spectrometry (EDS) mapping is employed to investigate the abrasion and adhesion mechanisms. The wear levels were reduced under the use of the hybrid approach; the decrease in flank wear value relative to the hybrid condition is 78%, 36%, and 27%, and in terms of crater wear, the reduction was 78%, 54%, and 48% over dry, MQL, and cryo CO2 conditions, respectively. Findings have portrayed that the lessening of temperature at the cutting area with the hybrid condition reduces the roughness by 58%, 44%, and 20% over dry, MQL, and cryo CO2 cutting strategies, respectively. Moreover, verdicts of the investigation confirm smaller grain size and high hardness under cryo cooling condition.Öğe Tribology-driven strategies for tool wear reduction and surface integrity enhancement in cryogenic CO2-cooled milling of laser metal deposited Ti64 alloy(Elsevier Sci Ltd, 2024) Ross, Nimel Sworna; Mashinini, Peter Madindwa; Ananth, M. Belsam Jeba; Srinivasan, N.; Gupta, Munish Kumar; Korkmaz, Mehmet ErdiAdditive manufacturing (AM) is chosen for its ability to streamline production processes and design freedom. This reduces material waste, enables rapid prototyping, and facilitates intricate geometries, ultimately offering cost-effective and customizable solutions for manufacturing complex components in diverse industries. Overlapping melting trajectories result in a low-quality surface (Ra=similar to 13.34 mu m) in the laser metal deposition (LMD) of the Ti64 alloy. Therefore, post-processing is often essential for AMed parts for engineering applications. Milling trials were conducted on AMed specimens under four environmental conditions: dry, flood, minimum quantity lubrication (MQL), and cryogenic medium. The machinability was evaluated in terms of the cutting temperature, machined surface roughness, tool wear, chip morphology, and microhardness. The flank wear under cryogenic CO2 condition is 52.78-54.29 % lower than dry condition, 33.86-36.24 % lower than flood cutting, and 23.64-26.86 % lower than MQL. The outcomes show that cryogenic cooling augments the tool life and the surface integrity of milling LMD parts. Moreover, the hardness under cryogenic CO2 was higher, indicating dimensional stability and maintenance of shape integrity under applied loads.
