Performance of MQL and Nano-MQL Lubrication in Machining ER7 Steel for Train Wheel Applications

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dc.authoridDemirsoz, Recep/0000-0003-0674-4572
dc.authoridKORKMAZ, Mehmet Erdi/0000-0002-0481-6002
dc.authoridBOY, MEHMET/0000-0003-2471-8001
dc.authoridPimenov, Danil/0000-0002-5568-8928
dc.authoridYASAR, NAFIZ/0000-0002-1427-1384
dc.contributor.authorCamli, Kerem Yavuz
dc.contributor.authorDemirsoz, Recep
dc.contributor.authorBoy, Mehmet
dc.contributor.authorKorkmaz, Mehmet Erdi
dc.contributor.authorYasar, Nafiz
dc.contributor.authorGiasin, Khaled
dc.contributor.authorPimenov, Danil Yurievich
dc.date.accessioned2024-09-29T16:08:07Z
dc.date.available2024-09-29T16:08:07Z
dc.date.issued2022
dc.departmentKarabük Üniversitesien_US
dc.description.abstractIn the rail industry, there are four types of steel grades used for monoblock wheels, namely ER6, ER7, ER8 and ER9. ER7 steel is manufactured in accordance with the EN13262 standard and is utilized in European railway lines. These train wheels are formed by pressing and rolling after which they are machined using turning process to achieve their final dimensions. However, machining ER7 steels can be challenging due to their high mechanical properties, which can facilitate rapid tool wear and thermal cracking. Therefore, while the use of coolants is critical to improving their machinability, using conventional flood coolants adds extra operational costs, energy and waste. An alternative is to use minimum quantity lubrication (MQL) cooling technology, which applies small amounts of coolant mixed with air to the cutting zone, leaving a near-dry machined surface. In the current study, preliminary tests were undertaken under dry conditions and using coated carbide inserts to determine the optimal cutting parameters for machining ER7 steel. The impact of the cutting speed and feed rate on surface roughness (R-a), energy consumption and cutting temperature were investigated and used as a benchmark to determine the optimal cutting parameters. Next, additional machining tests were conducted using MQL and nano-MQL cooling technologies to determine their impact on the aforementioned machining outputs. According to preliminary tests, and within the tested range of the cutting parameters, using a cutting speed of 300 m/min and a feed rate of 0.15 mm/rev resulted in minimal surface roughness. As a result, using these optimal cutting parameters with MQL and Nano-MQL (NMQL) cooling technologies, the surface roughness was further reduced by 24% and 34%, respectively, in comparison to dry conditions. Additionally, tool wear was reduced by 34.1% and 37.6%, respectively. The overall results from this study demonstrated the feasibility of using MQL coolants as a sustainable machining alternative for steel parts for rail wheel applications. In addition, the current study highlight the enhanced performance of MQL cooling technology with the addition of nano additives.en_US
dc.identifier.doi10.3390/lubricants10040048
dc.identifier.issn2075-4442
dc.identifier.issue4en_US
dc.identifier.scopus2-s2.0-85128222244en_US
dc.identifier.scopusqualityQ2en_US
dc.identifier.urihttps://doi.org/10.3390/lubricants10040048
dc.identifier.urihttps://hdl.handle.net/20.500.14619/7372
dc.identifier.volume10en_US
dc.identifier.wosWOS:000785348000001en_US
dc.identifier.wosqualityQ2en_US
dc.indekslendigikaynakWeb of Scienceen_US
dc.indekslendigikaynakScopusen_US
dc.language.isoenen_US
dc.publisherMdpien_US
dc.relation.ispartofLubricantsen_US
dc.relation.publicationcategoryMakale - Uluslararası Hakemli Dergi - Kurum Öğretim Elemanıen_US
dc.rightsinfo:eu-repo/semantics/openAccessen_US
dc.subjectER7 steelen_US
dc.subjectnano-MQLen_US
dc.subjectmachinabilityen_US
dc.subjectsurface roughnessen_US
dc.subjecttool wearen_US
dc.titlePerformance of MQL and Nano-MQL Lubrication in Machining ER7 Steel for Train Wheel Applicationsen_US
dc.typeArticleen_US

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